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How to: replace a belt-in-oil drive

By autotech-nath on May 12, 2017
Ford’s 1.8-litre TDCi engine uses two high tenacity (HT) ‘white’ belts: one for the timing drive system and the other in the belt-in-oil (BIO) system used to drive the fuel injection pump. Autotech 2017 technical assessment partner and drive system specialist, Dayco, reveals when and how it should be replaced.
As Ford’s power transmission supply partner, Dayco designed the world’s first BIO drive system in 2007, when it developed the engineering solution to supersede the previous chain-driven, high pressure injection pump for the popular 1.8-litre ‘Lynx’ engine, which had been widely used to power various Focus, C-Max, S-Max, Mondeo, Galaxy, Tourneo Connect and Transit Connect models between 1998 and 2013.

Although Ford only specify replacement of the injection pump drive components when the engine reaches 120,000 miles, Dayco recommends that, as industry best practice and to provide motorists added peace of mind, workshops follow the vehicle’s service interval for the scheduled timing drive replacement  and replace the injector pump drive at the same time. As well as avoiding the possibility of a subsequent failure, this policy allows workshops to update older units and replace their chain driven system with the latest BIO version, as it is a direct replacement.

Although the timing belt on this unit is one of the shortest in common use and the drive layout simple, some may be tempted to change just the belt, which can have catastrophic consequences. As a result, Dayco has addressed the importance of replacing all the drive components and following the correct installation process in a previous Technical Focus, which is available on request.
When it comes to the injection pump drive replacement, all the steps necessary for the timing drive replacement need to be followed, which endorses the fact that both should be replaced in unison. However, in
addition, the replacement requires the removal of the auxiliary belt idler pulley, injection pump timing drive pulley and the crankshaft pulley, the bolt for which should be discarded, this will allow the removal of the injection drive cover.
1) Remove the injection drive tensioner, then the gearwheel and the guide plates, which should allow the
removal of the belt and the gear on the crankshaft. Dayco BIO kit KBIO01 provides all the components
– crankshaft and injection pump gearwheels, belt guides and belt – in a single replacement ‘cartridge’; for
which the belt guide bolts should be tensioned to 23 Nm and the gearwheel bolt to 50 Nm. Once installed, fit a new Dayco hydraulic tensioner ATB2635 and tension to 65 Nm.
2) Refit the cover, followed by the auxiliary belt idler, which should be tensioned to 48 Nm. Replace the
existing crankshaft oil seal with a new seal and refit the crankshaft pulley, using a new bolt, which needs to
be tightened to 100 Nm. Refit the injection pump pulley and tension the bolts to 24 Nm and replace the rest
of the items, including all the timing drive components contained in Dayco Timing Belt Kit KTB470 & KTB251.
For more information regarding the OEM quality power transmission products in the Dayco range, please email: or visit:
Test your knowledge now HERE and receive training material, along with your score and correct answers.


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