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Gates Technical Bulletin
Gates Technical Bulletin
www.gates.com/europe/technical
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mistakes
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Technical
Bulletins
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Page
5
9
11
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21
23
25
29
33
39
41
45
47
49
53
55
57
59
61
67
69
71
77
In order of make
Make
Alfa Romeo
Audi
Model
Page
147, 156, GT
45
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
Citron
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, Dobl, 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
www.gates.com/europe/technical
www.gates.com/europe/technical
# 001
28/02/2005
MAKE :
MODEL :
MOTOR :
MOTOR CODE :
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 Oclock, L-cam: 3 Oclock, R-cam: 9
Oclock 5368XS/5408XS/5461XS/5542XS: crankshaft: 6 Oclock,
camshafts 12 Oclock.
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 antiFig. 1
clockwise starting at crankshaft
Page 1 of 3
# 001
28/02/2005
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
belt teeth in the
Fig. 2
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
Fig. 3
position. If correct (in V)
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.
# 001
28/02/2005
arm
Fig. 4
Page 3 of 3
www.gates.com/europe/technical
# 002
25/03/2005
MOTOR :
MOTOR CODE :
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 !
Page 1 of 1
10
www.gates.com/europe/technical
# 003
GATES REFERENCE :
MAKE :
MODEL :
MOTOR :
MOTOR CODE :
29/04/2005
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.
Page 1 of 1
11
12
www.gates.com/europe/technical
# 004
GATES REFERENCE :
MAKE :
MODEL :
MOTOR :
MOTOR CODE :
27/06/2005
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 ( 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).
Retaining
pin
Oblong hole
adjustment
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.
Page 1 of 1
13
14
www.gates.com/europe/technical
# 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.
Page 1 of 2
15
# 005
11/08/2005
Fig. 1
Fig. 2
Checkmark
16
# 006
MODEL :
MOTOR :
MOTOR CODE ::
07/11/2005
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. 2: PJ belt
Page 1 of 2
17
# 006
07/11/2005
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 Partners website.
18
#007
27/11/2005
MOTOR :
MOTOR CODE :
Page 1 of 1
19
20
www.gates.com/europe/technical
# 008
28/12/2005
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
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.
Page 1 of 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.
# 008
28/12/2005
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
# 009
29/12/2005
GATES REFERENCE :
MAKE :
MODEL :
MOTOR :
MOTOR CODE :
Page 1 of 4
23
24
www.gates.com/europe/technical
# 010
GATES REFERENCE :
MAKE :
MODEL :
MOTOR :
MOTOR CODE :
24/02/2006
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
Page 1 of 4
25
# 010
24/02/2006
Fig. 2
OE 058109243E
Fig. 3
OE 058109243D
26
# 010
24/02/2006
Belt
Tensioner (A)
Hydr. actuator (B)
Idler (C)
OE ref. 058198479
058109119C
058109243E
058109479B
058109244 (not in OE
kit)
K025492XS
included
included
included
included
K015492XS
included
included
not 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
AUDI
AUDI
AUDI
Model
A4
A4
A4
CC
1.8
1.8
1.8
AUDI A4 Quattro
AUDI A4 Quattro
AUDI A4 Quattro
1.8
1.8
1.8
AUDI A6
1.8
AUDI A6
AUDI A6
AUDI A6 Quattro
1.8
1.8
1.8
AUDI
AUDI
VW
VW
VW
VW
1.8
1.8
1.8
1.8
1.8
1.8
VW
VW
A6 Quattro
Cabriolet
Passat
Passat
Passat
Passat
Estate/Variant
Passat
Estate/Variant
Passat
Estate/Variant
Engine code
From Till
AFY
7/95 9/00
ADR/AEB
10/94 7/99
AJL/ANB/APT/
8/97 9/00
APU/ARG/ARK/
AVV
AFY
8/97 9/00
ADR/AEB
11/94 7/99
AJL/ANB/APT/
8/97 9/00
APU/ARG/ARK
AEB/AJL/ANB/
5/97 5/01
APU/ARK
AFY
5/97 5/00
ADR
8/95 1/98
AEB/AJL/ANB/
5/97 5/01
APU/ARK
ADR
8/96 4/97
ADR
4/97 8/00
AEB
11/96 12/98
AFY/ANB/APU
11/96 8/00
ADR/APT/ARG
11/96 8/00
AEB
5/97 12/98
1.8 AFY
5/97
8/00
1.8 ADR
5/97
8/00
Chassis number
8D-T-155001
8D-T-155001
8D-T-155001
Page 3 of 4
27
# 010
24/02/2006
Belt
Tensioner (A)
Hydr. actuator (B)
Idler (C)
OE ref. 058198479A
058109119C
058109243D
058109479B
058109244 (not in OE kit)
K045492XS
included
included
included
included
K035492XS
included
included
not 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
AUDI
AUDI
AUDI
Model
A4
A4
A4 Quattro
CC
1.8
1.8
1.8
Engine code
AFY
ADR/AEB
ADR/AEB
From
7/1995
10/1994
11/1994
Till
Chassis number
9/2000
8D-T-155000
7/1999
8D-T-155000
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
wv 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
1997 = v
1998 = w
1999 = x
28
2000 = y
2001 = 1
2002 = 2
etc
Hydraulic Tensioners
# 011
GATES REFERENCE :
MAKE :
MODEL :
MOTOR :
MOTOR CODE :
Hydraulic Tensioners
FORD / OPEL / VOLKSWAGEN GROUP
MULTIPLE
31/03/2006
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.
Page 1 of 4
29
Fig. 1
Fig. 2
Tensioner
Pulley
# 011
31/03/2006
Lever
Hydraulic
Actuator
30
Retaining pin
# 011
Piston
Rod
Cylinder
31/03/2006
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.
Page 3 of 4
31
Advantages
# 011
31/03/2006
32
# 012
31/03/2006
MOTOR :
MOTOR CODE :
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
Page 1 of 6
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.
# 012
31/03/2006
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.
# 012
31/03/2006
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
Page 3 of 6
35
Possible errors
# 012
31/03/2006
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.
# 012
31/03/2006
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
Page 5 of 6
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.
# 012
31/03/2006
Marks on
engine
caused by 4th
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 N2 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
# 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
Page 1 of 2
39
Measure the tension in the bottom span, between the crankshaft and
power steering pump (or idler for cars without power steering) (Fig.1).
# 013
21/04/2006
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
# 014
24/04/2006
MOTOR :
MOTOR CODE :
OE ref. 46792898
OE ref. 46416489
OE ref. 71734799
Fig. 1
Fig. 2
Technical Bulletin 014
Copyright 2006 Gates Corporation
www.gates.com/europe/technical
Page 1 of 3
41
# 014
24/04/2006
Fig. 3
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
Fig. 5
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
42
Fig. 7
# 014
24/04/2006
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.
Page 3 of 3
43
44
www.gates.com/europe/technical
# 015
13/07/2007
MOTOR :
MOTOR CODE :
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.
Page 1 of 2
45
# 015
13/07/2006
Make
ALFA
ROMEO
Model
Stroke
Type
Engine
code
KW
Year
From
Month
From
Year
Till
Month
Till
Article
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
ALFA
ROMEO
145
1.9
JTD
AR32302
77
1999
03
2001
10
6PK1795
ALT
+ AC
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
146
1.9
JTD
AR32302
77
1999
03
2001
10
6PK1795
ALT
+ AC
147
1.9
JTD
937A2000
85
2001
06
2005
08
6PK1038
ALT
- AC
147
1.9
JTD
937A2000
85
2001
06
2005
08
6PK1835XQ
ALT
+ AC
147
1.9
JTD
192A5000
103
2002
07
2005
05
6PK1835XQ
ALT
147
1.9
JTD
182B9000
74
2002
11
6PK1038
ALT
- AC
147
1.9
JTD
182B9000
74
2002
11
6PK1835XQ
ALT
+ AC
147
1.9
JTD
937A4000
93
2003
08
6PK1835XQ
ALT
147
1.9
JTD
192B1000/
937A5000
100
/110
2004
04
2005
08
6PK1835XQ
ALT
156
1.9
JTD
AR32302
77
1997
11
2000
06
6PK1038
ALT
- AC
156
1.9
JTD
AR32302
77
1997
11
2000
06
6PK1835XQ
ALT
+ AC
156
1.9
JTD
AR37101
81
2000
05
2002
02
6PK1038
ALT
- AC
156
1.9
JTD
AR37101
81
2000
05
2002
02
6PK1835XQ
ALT
+ AC
156
1.9
JTD
937A2000
85
2001
11
2005
09
6PK1835XQ
ALT
156
1.9
JTD
192A5000
103
2002
11
2004
11
6PK1835XQ
ALT
156
156 Sport
wagon
156 Sport
wagon
156 Sport
wagon
156 Sport
wagon
156 Sport
wagon
156 Sport
wagon
156 Sport
wagon
1.9
JTD
937A4000
93
2003
11
2005
09
6PK1835XQ
ALT
1.9
JTD
AR32302
77
1999
10
2000
04
6PK1038
ALT
GT
Marea
Marea
S.W./
Weekend
Marengo
(Marea)
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
ALFA
ROMEO
2005
05
05/98-
- AC
1.9
JTD
AR32302
77
1999
10
2000
04
6PK1835XQ
ALT
+ AC
1.9
JTD
AR37101
81
2000
05
2002
02
6PK1038
ALT
- AC
1.9
JTD
AR37101
81
2000
05
2002
02
6PK1835XQ
ALT
+ AC
1.9
JTD
85
2001
05
2006
05
6PK1835XQ
ALT
1.9
JTD
937A2000
192A5000/
937A4000
93/103
2002
11
2006
05
6PK1835XQ
ALT
1.9
JTD
937A5000
110
2004
01
2006
05
6PK1835XQ
ALT
1.9
JTD
110
2003
11
6PK1835XQ
ALT
1.9
JTD
77/81
1999
03
2002
08
6PK1835XQ
ALT
+ AC
1.9
JTD
74/77/
81
1999
03
2003
06
6PK1835XQ
ALT
+ AC
1.9
JTD
77/81
1999
03
2002
08
6PK1835XQ
ALT
+ AC
1.9
JTD
77/81/
85
1998
08
6PK1835XQ
ALT
+ AC
FIAT
Multipla
Multipla
Van
937A5000
182B4000/
186A6000
182B4000/
182B9000/
186A6000
182B4000/
186A6000
182B4000/
186A6000/
186A8000
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
Lybra
Estate/
Wagon
Lybra
Estate/
Wagon
1.9
JTD
937A2000
85
2000
10
2005
10
6PK1835XQ
ALT
+ AC
1.9
JTD
AR32302/
AR37101
77/81
1999
07
2001
09
6PK1835XQ
ALT
+ AC
1.9
JTD
937A2000
85
2000
10
2005
10
6PK1835XQ
ALT
+ AC
FIAT
FIAT
FIAT
FIAT
LANCIA
LANCIA
46
Appli
cation
Attri
butes
>>>
->|MTR
NR
1370829
|->MTR
NR
1370830
->|MTR
NR
1370829
|->MTR
NR
1370830
# 016
01/08/2006
# 009
29/12/2005
GATES REFERENCE :
MAKE :
MODEL
:
PowerGrip
Kit
MOTOR :
MOTOR
CODE : : :
GATES REFERENZ
MARKE :
MODEL :
MOTOR TYP :
MOTOR CODE :
SinceTechnical
the launchBulletin
of our K015541XS
duringby2003,
this kitBulletin
has always
016 is replaced
Technical
027.
contained an automatic tensioner for these Ford 1.8 diesel applications.
Please
consult
Technical
bulletin
009www.gates.com/europe/technical
is replaced with Technical bulletin 25
The very first models offor
theup-to-date
Ford Focusinformation.
and Ford Fiesta, however, were
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
Fig. 1
New automatic tensioner
Fig. 1 shows the old manual tensioner on the right side and the new
automatic tensioner on the left.
Page 1 of 2
47
48
www.gates.com/europe/technical
# 017
MAKE:
MODEL:
ENGINE:
ENGINE CODE:
16/02/07
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.
Page 1 of 3
49
# 017
16/02/07
Fig. 3
Fig. 4
or
B) on a sticker situated on the timing belt cover (Fig. 5)
Fig. 5
50
# 017
16/02/07
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
PowerGrip belt
5212XS
5485XS
5486XS
5552XS
Page 3 of 3
51
52
www.gates.com/europe/technical
# 018
ENGINE:
ENGINE CODE:
09/03/07
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)
with airconditioning:
o belt has to be on the outside of the pulleys (Fig. 2)
Page 1 of 2
53
# 018
09/03/07
Fig. 1
Fig. 2
54
ENGINE:
ENGINE CODE:
1.9 Diesel
Various engine codes
GATES REFERENCE:
# 019
16/05/07
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
Page1 of 2
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.
# 019
16/05/07
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
56
# 020
09/11/07
GATES REFERENCE:
Various.
MAKE:
MODEL:
ENGINE:
ENGINE CODE:
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.
Page1 of 1
57
58
www.gates.com/europe/technical
# 021
GATES REFERENCE:
MAKE:
MODEL:
ENGINE:
ENGINE CODE:
07/12/07
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.
Page 1 of 2
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.
# 021
07/12/07
In summary:
If the drawing on the box only has the
If the drawing on the box has the
60
# 022
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
02/06/08
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)
Page 1 of 5
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.
# 022
02/06/08
Fig. 2
Fig. 3
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
# 022
02/06/08
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).
Page 3 of 5
63
# 022
02/06/08
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)
Fig. 9
7. tighten the water pump bolts
8. re-install engine support
9. re-install the removed auxiliary belt crankshaft pulley
Conclusion:
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)
# 022
02/06/08
OE
Fig. 10
OE
Fig. 11
Counterfeit
Fig. 12
Visit our web catalogue : www.gatesautocat.com
Page 5 of 5
65
66
www.gates.com/europe/technical
# 023
18/08/08
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.
Page1 of 2
67
# 023
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
18/08/08
Fig. 3
Applications overview:
K025468XS
CITROEN
CITROEN
CITROEN
CITROEN
CITROEN
CITROEN
CITROEN
FIAT
PEUGEOT
PEUGEOT
PEUGEOT
PEUGEOT
PEUGEOT
PEUGEOT
PEUGEOT
Evasion
Synergie
XM
Xantia
Xsara
Xsara
ZX
Ulysse
306
306
306 Cabrio
406
406 Coupe
605
806
K035468XS
CITROEN
CITROEN
CITROEN
CITROEN
CITROEN
PEUGEOT
PEUGEOT
PEUGEOT
PEUGEOT
Xantia
Xantia
Xsara
Xsara Estate/Break
ZX
306
306 Cabrio
406
406 Coupe
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
B
L
B
B
B
B
B
B
B
1.8
1.8
1.8
1.8
1.8
1.8
1.8
1.8
1.8
XU10J4R
XU10J4R
XU10J4R
XU10J4R
XU10J4RS
XU10J4R
XU10J4RS
RFV
XU10J4RS
XU10J4R
XU10J4R
XU10J4R
XU10J4R
XU10J4R
XU10J4R
XU7JP4
XU7JP4LPG
XU7JP4
XU7JP4
XU7JP4
XU7JP4
XU7JP4
XU7JP4
XU7JP4
9
9
8
6
1
1
9
9
5
5
5
11
5
7
10
1999
2000
1994
1995
1998
1998
1996
1998
1997
1997
1997
1996
1997
1994
1998
6
1
7
5
4
5
5
8
10
1995
1998
1997
1998
1996
1997
1997
1995
1997
10
12
4
10
10
8
10
8
5
10
12
8
12
9
2
4
12
8
8
10
4
12
8
3
2002
2001
2000
2002
2004
2000
1997
2000
2001
2001
2002
2000
1999
1999
2003
2003
2000
2000
2000
1997
2002
2002
2000
1999
68
# 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
Fig. 1
-
Fig. 2
Page1 of 2
69
# 024
25/08/08
The procedure will be visualised on the PowerGrip Kit and belt box label
as in Fig 3.
Fig. 3
70
# 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
Page 1 of 5
71
# 025
23/10/08
K015563XS
5563XS
K025563XS
5563XS
ALL engines
K035563XS
5563XS
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
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.
# 025
23/10/08
Spring
4)
Fig. 5
5) Rotate tensioner anticlockwise (Allen key) till Allen key hole is in
+/- 5 oclock 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
Page 3 of 5
73
# 025
23/10/08
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)
2)
3)
4)
5)
6)
7)
8)
9)
10)
74
# 025
23/10/08
, (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
Technical Bulletin 025
Copyright 2008 Gates Corporation
www.gates.com/europe/technical
Page 5 of 5
75
76
www.gates.com/europe/technical
# 026
17/11/2008
MAKE :
MODEL :
ENGINE :
ENGINE CODE :
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
www.gates.com/europe/technical
Page 1 of 3 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).
# 026
17/11/2008
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
www.gates.com/europe/technical
Page 2 of 3
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.
# 026
17/11/2008
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
www.gates.com/europe/technical
Page 3 of 379
Caution
Use Gates products only on applications specified in Gates literature. Install and maintain the products according to the vehicle manufacturers 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.
80
www.gates.com/europe/technical
Dr. Carlierlaan 30
B - 9320 Erembodegem
Belgium
TL : (32) 53 / 76 27 11
FX : (32) 53 / 76 27 13
inforequest@gates.com
Polgono Industrial
Les Malloles
E - 08660 Balsareny
(Barcelona)
Espaa
TL : (34) 93 / 877 70 00
FX : (34) 93/ 877 70 39
GATES POWERTRAIN
2, Rue de la Briqueterie
B.P. 37
Zone Industrielle
F - 95380 Louvres
France
TL : (33) 1 / 34 47 41 41
FX : (33) 1 / 34 72 60 54
GATES S.R.L.
Via Senigallia 18
(Int. 2 - Blocco A - Edicio 1)
I - 20161 Milano MI
Italia
TL : (39) 02 / 662 16 21
FX : (39) 02 / 645 86 36
GATES HOMEPAGE
http://www.gates.com/europe