E2 Technical Bulletin

E2/70503
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Avoid costly
mistakes
Whether you‘re a garage mechanic, an automotive
thanks to Gates engineer, a dealer or a car manufacturer, you are
undoubtedly confronted with the increasing
Technical technological complexity of modern-day engines.
Vehicles have evolved in such a way that many
Bulletins 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.
www.gates.com
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 www.gates.com/europe/technical
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 2.4 / 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
Mazda 121 13
Mercedes Various models 17
Mitsubishi Various models with Renault 1.9 Diesel motor 55
Opel Various models 29
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
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
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
www.gates.com/europe/technical 3
Installation recommendations for timing system on GM 1.4,
1.6, 1.8, 2.0, 2.2 16V engines
GATES REFERENCE : 5368XS, 5369XS, 5408XS, 5461XS, 5499XS,
5542XS
MAKE : OPEL / VAUXHALL
MODEL : Astra, Calibra, Combo, Corsa, Cavalier,
# 001 Frontera, Kadett, Meriva, Omega, Signum,
Sintra, Tigra, Vectra, Zafira
28/02/2005 MOTOR : 1.4, 1.6, 1.8, 2.0, 2.2 16V
MOTOR CODE : 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 anti-
clockwise starting at crankshaft Fig. 1
Technical Bulletin 001 Copyright © 2006 Gates Corporation Page 1 of 3

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)
# 001 10. Unblock
28/02/2005 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.
Technical Bulletin 001

Copyright © 2006 Gates Corporation Page 2 of 3
# 001
28/02/2005
arm
Fig. 4

VAG 1.9 Diesel – Timing belts 5543XS and 5559XS
GATES REFERENCE : 5543XS and 5559XS

MAKE : AUDI / SEAT / SKODA / VOLKSWAGEN
MODEL : A3, Bora, Caddy, Cordoba, Fabia, Golf,
Ibiza, Inca, Leon, New Beetle, Octavia,
Polo, Toledo
# 002 MOTOR :
MOTOR CODE :
1.9 SDi / TDi
AYQ, AGP, AQM, AGR, ASY, ASV, ALH,
25/03/2005 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 !

Ford Transit 2.5 Diesel, Turbo Diesel Timing Belts/Kits
GATES REFERENCE : 5571XS and 5572XS

MAKE : FORD
MODEL : Tourneo, Transit
MOTOR : 2.5 D / TD
MOTOR CODE : 4BC, 4CC, 4DA, 4EA, 4EB, 4EC, 4FA,
# 003 4FD, 4GA, 4GC, 4GD, 4HA, S1
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.

K025433XS for Ford 1.2, 1.4 and 1.6 engines
GATES REFERENCE : K025433XS

MAKE : FORD / MAZDA
MODEL : Fiesta, Focus, Fusion, Puma, 121
MOTOR : 1.2, 1.4, 1.6
MOTOR CODE : ZH12FUJA, ZH12FUJB ;
# 004 ZH14ASDA, ZH14FXDB, ZH14FXDC,

ZH14FXDD, ZH14FXJA, ZH14FXJB, ZH14EFI ;
27/06/2005 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).
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.

K015571XS/K015572XS for Ford Transit 2.5 D
GATES REFERENCE : K015571XS / K015572XS
MAKE : FORD
MODEL : Tourneo, Transit
MOTOR : 2.5 D / TD
MOTOR CODE : 4BC, 4CC, 4DA, 4EA, 4EB, 4EC, 4FA,
# 005 4FD, 4GA, 4GC, 4GD, 4HA, S1
11/08/2005
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).

# 005
11/08/2005
Fig. 1 Fig. 2
Allen key hole
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.

Micro-V® XF belts – PJ profile
GATES REFERENCE : Micro-V XF belts – PJ profile

MAKE : AUDI / SEAT / VOLKSWAGEN /
MERCEDES
MODEL : MULTIPLE
MOTOR :
# 006 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. 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.

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
# 006 close to the front of the car).
07/11/2005
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.

5223XS/5622XS and kits
GATES REFERENCE : 5223XS / 5622XS and kits
MAKE : AUDI / SEAT / VOLKSWAGEN
MODEL : 80, A4, Alhambra, Cabrio, Caddy,
Campmobile, Caravelle, Cordoba, Ibiza,
Inca, Toledo, Golf, Passat, Polo, Sharan,
#007 MOTOR :
Transporter, Vento
1.7 , 1.9 D / TD / SDi / TDi
27/11/2005 MOTOR CODE : 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’.

K035040/K045040 for Renault/Jeep 2.1D, TD
GATES REFERENCE : K035040 / K045040
MAKE : JEEP / RENAULT
MODEL : Cherokee, Comanche / 18, 20, 21, 25, 30,
Espace, Fuego, Master, Trafic
MOTOR : 2.1 D / TD
# 008 MOTOR CODE : 52710, 852702, 852750, B210, J8S02, J8S240,

J8S330, J8S610, J8S612, J8S620, J8S622,
28/12/2005 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 Fig. 3
OE ref.7700871169
The new tensioner exists out of 2 parts (Fig. 3), which have to be put
together as shown in Fig. 2.

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.
# 008 Correct installation is possible using the following procedure:
28/12/2005
* 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

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

Timing Belt System replacement on VAG 1.8 20V engines
(PowerGrip® Belt and Kits 5492XS)
GATES REFERENCE : PowerGrip and kit 5492XS
MAKE : AUDI / VOLKSWAGEN
MODEL : A4, A6, Cabrio, Passat
MOTOR : 1.8, 1.8 – 20v T
# 010 MOTOR CODE : AEB, ADR, AFY, AJL, ANB, ARG, ARK,
APT, APU, AVV
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

(A) Tensioner 058109243D or
058109243E
(B) Hydraulic Actuator 058109479B
(C) Idler 058109244
# 010
24/02/2006
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.

Composition and applications
OES Kit 058198479 - K025492XS
OE ref. 058198479 K025492XS K015492XS

# 010 Belt
Tensioner (A)
058109119C
058109243E
included
included
included
included
24/02/2006
Hydr. actuator (B) 058109479B included not included
Idler (C) 058109244 (not in OE included included
kit)
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 1.8 AEB 5/97 12/98
Estate/Variant
VW Passat 1.8 AFY 5/97 8/00
Estate/Variant
VW Passat 1.8 ADR 5/97 8/00
Estate/Variant

OES Kit 058198479A - K045492XS
OE ref. 058198479A K045492XS K035492XS

# 010 Belt
Tensioner (A)
058109119C
058109243D
included
included
included
included
24/02/2006
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
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 2000 = y
1997 = v 2001 = 1
1998 = w 2002 = 2
1999 = x etc…

Hydraulic Tensioners
GATES REFERENCE : Hydraulic Tensioners

MAKE : FORD / OPEL / VOLKSWAGEN GROUP
MODEL : MULTIPLE
MOTOR :
MOTOR CODE :
# 011
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.

Fig. 1 Fig. 2
Tensioner
# 011 Pulley
31/03/2006
Lever
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.

Retaining pin
Piston
Rod Cylinder
# 011
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.

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,
# 011 unidirectional damping characteristics make it suitable for controlling the
31/03/2006
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 - K016PK1903 : Opel Vectra 2.0 DTI 1996 -
2003 2003
Please consult our catalogues for more detailed application information.

Installation of tensioner used in PowerGrip® Kits
K015543XS, K025543XS and K015559XS
GATES REFERENCE : K015543XS, K025543XS and K015559XS
MAKE : AUDI / SEAT / SKODA / VOLKSWAGEN
MODEL : A3, Cordoba, Ibiza, Inca, Leon, Toledo, Octavia,
Bora, Caddy, Golf, New Beetle, Polo
# 012 MOTOR :
MOTOR CODE :
1.9 SDi / TDi
AGP, AGR, AHF, ALH, AQM, ASV, ASY, AYQ
31/03/2006
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

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 re-
check the tensioner pointer. Do not skip this step!

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.
# 012
31/03/2006
When you are in the tension-setting, never turn the tensioner
anti-clockwise!
Index tab
Fig. 3
Pointer
Fig. 4

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
# 012 tensioning process.
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

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

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 Marks on
31/03/2006
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 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.

Accessory drive on Renault 1.5 DCi engines
GATES REFERENCE : Accessory drive

MAKE : RENAULT
MODEL : Clio II, Express, Kangoo, Rapid, Symbol
MOTOR : 1.5 dCi
MOTOR CODE : K9K700, K9K702, K9K710
# 013
21/04/2006
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 (torx-
head) 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

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.

PowerGrip® Kit K015432XS for Fiat and Lancia 1.6
petrol engines
MAKE : FIAT / LANCIA
MODEL : Albea, Brava, Bravo, Doblò, Marea,
Multipla, Palio, Siena, Stilo, Delta, Lybra
# 014 MOTOR :
MOTOR CODE :
1.6 benzine, LPG, BiPower
178B3000, 182A4000, 182A6000, 182B5098,
24/04/2006 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

# 014
24/04/2006
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

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).
# 014 At that moment the two black marks (F) will also be aligned. Only then the
24/04/2006
tensioner is correctly installed.

Fiat group 1.9 JTD engines
GATES REFERENCE : 6PK1835XQ for OE ref. 55189679 and
71734476
MAKE : ALFA ROMEO / FIAT / LANCIA
MODEL : 147, 156, GT, Marea, Marengo, Multipla,
Lybra
# 015 MOTOR :
MOTOR CODE :
1.9 JTD
182B4000, 186A6000, 186A8000, 186A9000,
13/07/2007 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.

Appli
cation
Attri
Stro- Engine Year Month Year Month butes
Make Model ke Type code KW From From Till Till Article >>>
ALFA
ROMEO 145 1.9 JTD AR32302 77 1999 03 2001 10 6PK1038 ALT - AC
->|MTR
ALFA NR
ROMEO 145 1.9 JTD AR32302 77 1999 03 2001 10 6PK1778 ALT + AC 1370829
|->MTR
ALFA NR
# 015
ALFA
13/07/2006 ALFA
->|MTR
NR
|->MTR
ALFA NR
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
ALFA 192B1000/ 100

ROMEO 147 1.9 JTD 937A5000 /110 2004 04 2005 08 6PK1835XQ ALT
ALFA
ALFA
ROMEO 156 1.9 JTD AR32302 77 1997 11 2000 06 6PK1835XQ 05/98- ALT + AC
ALFA
ALFA
ROMEO 156 1.9 JTD AR37101 81 2000 05 2002 02 6PK1835XQ ALT + AC
ALFA
ALFA
ALFA
ALFA 156 Sport
ROMEO wagon 1.9 JTD AR32302 77 1999 10 2000 04 6PK1038 ALT - AC
ALFA 156 Sport
ROMEO wagon 1.9 JTD AR32302 77 1999 10 2000 04 6PK1835XQ ALT + AC
ALFA 156 Sport
ROMEO wagon 1.9 JTD AR37101 81 2000 05 2002 02 6PK1038 ALT - AC
ALFA 156 Sport
ROMEO wagon 1.9 JTD AR37101 81 2000 05 2002 02 6PK1835XQ ALT + AC
ALFA 156 Sport
ROMEO wagon 1.9 JTD 937A2000 85 2001 05 2006 05 6PK1835XQ ALT
ALFA 156 Sport 192A5000/
ROMEO wagon 1.9 JTD 937A4000 93/103 2002 11 2006 05 6PK1835XQ ALT
ALFA 156 Sport
ROMEO wagon 1.9 JTD 937A5000 110 2004 01 2006 05 6PK1835XQ ALT
ALFA
ROMEO GT 1.9 JTD 937A5000 110 2003 11 6PK1835XQ ALT
182B4000/
FIAT Marea 1.9 JTD 186A6000 77/81 1999 03 2002 08 6PK1835XQ ALT + AC
Marea 182B4000/
S.W./ 182B9000/ 74/77/
FIAT Weekend 1.9 JTD 186A6000 81 1999 03 2003 06 6PK1835XQ ALT + AC
Marengo 182B4000/
FIAT (Marea) 1.9 JTD 186A6000 77/81 1999 03 2002 08 6PK1835XQ ALT + AC
182B4000/
186A6000/ 77/81/
FIAT Multipla 1.9 JTD 186A8000 85 1998 08 6PK1835XQ ALT + AC
Multipla
FIAT Van 1.9 JTD 186A8000 85 2002 04 6PK1835XQ ALT + AC
AR32302/
LANCIA Lybra 1.9 JTD AR37101 77/81 1999 07 2001 09 6PK1835XQ ALT + AC
LANCIA Lybra 1.9 JTD 937A2000 85 2000 10 2005 10 6PK1835XQ ALT + AC

Lybra
Estate/ AR32302/
LANCIA Wagon 1.9 JTD AR37101 77/81 1999 07 2001 09 6PK1835XQ ALT + AC
Lybra
Estate/
LANCIA Wagon 1.9 JTD 937A2000 85 2000 10 2005 10 6PK1835XQ ALT + AC

PowerGrip® Kit K015541XS for Ford 1.8 diesel
engines
MAKE : FORD
PowerGrip
MODEL : ® Kit K015563XS
Courier, Fiesta, Focus, Tourneo, Transit
MOTOR : 1.8 TDDi / TDCi
# 016 MOTOR CODE : : :
GATES REFERENZ
MARKE :
LD18RTN,
PowerGripLD18RTP,
LD18BHDB,
LD18BHDA,
Kit K015563XS
LD18C9DA,
OPEL / VAUXHALL LD18C9DB,
01/08/2006 LD18C9DC, YD18F9DA, YD18F9DB,
MODEL : Astra, Combo, Corsa, Meriva
MOTOR TYP : YD18FFDA, YD18BHPA,
1.7 Di / DTi (ISUZU) YD18HCPA,
/ CDTi
MOTOR CODE : YD18HCPB,
Y17DT, Y17DTL, Z17DTH YD18BHPB
YD18HCPC,
# 009
29/12/2005 SinceTechnical
the launchBulletin
of our K015541XS duringby2003,
016 is replaced this kitBulletin
Technical has always
027.
!contained an automatic tensioner for these Ford 1.8 diesel applications.
TechnicalPlease consult
bulletin 009www.gates.com/europe/technical
The very first models offor
is replaced with Technical bulletin 25
theup-to-date
Ford Focusinformation.
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.
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 Old manual tensioner
Fig. 1 shows the old manual tensioner on the right side and the new
automatic tensioner on the left.

Volvo S40/V40 models with 1.9 diesel engine
GATES REFERENCE: PowerGrip® belts 5212XS, 5485XS, 5486XS,
5552XS
MAKE: VOLVO
MODEL: S40, V40
ENGINE: 1.9TD, TDi, DiTD
# 017 ENGINE CODE: D4192T, D4192T2, D4192T3, D4192T4
16/02/07
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.

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).
# 017
16/02/07
Fig. 3
Fig. 4
or
B) on a sticker situated on the timing belt cover (Fig. 5)
Fig. 5
BUT, the engine code is also “hidden” in the chassis number:
The 6th and 7th 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
# 017 So chassis number *YV1VW73……….* means the car has a D4192T2
16/02/07
engine.
In summary:
Engine code PowerGrip® belt
D4192T (up to engine number 3534) 5212XS

(from engine number 3535) 5485XS
D4192T2 5486XS
D4192T3 and T4 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
Technical Bulletin 017 Copyright © 2007 Gates Corporation Page 3 of 3 51
5 and 6 PK Micro-V® XF belts on Renault engines
GATES REFERENCE: Various Micro-V® XF belts/Kit K015PK1750
MAKE: RENAULT
MODEL: Clio, Kangoo, Laguna, Logan, Megane, Modus,
Scenic, Thalia
ENGINE: 1.4, 1.6, 1.8, 2.0 Petrol, 1.5 DCi
# 018 ENGINE CODE: F4P, F4R, F5R, K4J, K4M, K7J, K7M, K9K
09/03/07
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:

1.5 DCi:

# 018
09/03/07
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.

Selecting timing belts/kits for the Renault 1.9D engine
GATES REFERENCE: 5212/XS, 5305XS, 5484XS, 5485/XS, 5486XS,
5561XS and their kits.
MAKE: Mitsubishi, Opel/Vauxhall, Renault, Volvo
MODEL: Various models with Renault 1.9 Diesel engine
# 019 ENGINE:
ENGINE CODE:
1.9 Diesel
Various engine codes
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
Technical Bulletin 019 Copyright © 2007 Gates Corporation Page1 of 2

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
# 019 course the production date of the car. But when a car was sold within the
16/05/07
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.

Copyright © 2007 Gates Corporation Page2 of 2
VAG Timing System Replacement Intervals
GATES REFERENCE: Various.
MAKE: AUDI, SEAT, SKODA, VOLKSWAGEN

MODEL: All
ENGINE: All
# 020 ENGINE CODE: All
09/11/07
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.

Additional tension values for STT-1
GATES REFERENCE: 5078, 5344XS. K015078, K01/K025344XS
MAKE: AUDI, BMW
MODEL: Various
ENGINE: Audi 2.6/2.8 V6; BMW 2.4 D/TD
ENGINE CODE: Audi AAH,ABC,ACZ,AEJ, AFC;
# 021 BMW M21246TA/TB
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.

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:
# 021 If the drawing on the box only has the , then use the belt part number.
07/12/07
If the drawing on the box has the , then use this number.

Tensioning issues on Chevrolet/Daewoo 16V petrol engines
GATES REFERENCE: 5419XS/K015419XS
MAKE: Chevrolet/Daewoo
MODEL: Aranos, Assol, Aveo, Cielo, Espero, Kalos,
Lacetti, Lanos, Nexia, Nubira, Rezzo, Tacuma
ENGINE: 1.4 16V, 1.5 16V, 1.6 16V
# 022 ENGINE CODE: 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)
• 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

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
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)
Technical Bulletin 022Copyright © 2008 Gates Corporation Page 2 of 5
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.
# 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).
Fig. 6 View from front Fig. 7 View from back

# 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:
• 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

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 OE
Fig. 10 Fig. 11
Counterfeit
Fig. 12
K02/K035468XS for PSA 1.8 and 2.0 16V engines
GATES REFERENCE: K02/035468XS
MAKE: CITROEN / FIAT / PEUGEOT
MODEL: Evasion, Synergie, XM, Xantia, Xsara, ZX,
Ulysse, 306, 406, 605, 806
ENGINE: 1.8 16V, 2.0 16V
# 023 ENGINE CODE: XU7JP4, XU10J4R, XU10J4RS,

RFV
18/08/08
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).

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
# 023
18/08/08
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
Tension setting procedure for PSA 2.0 HDI engines
GATES REFERENCE: 5588XS/K015588XS/K025588XS/KP15588XS
MAKE: CITROEN, FIAT, LANCIA, PEUGEOT, SUZUKI
MODEL: Various
ENGINE: 2.0 HDI, 2.0 JTD
ENGINE CODE: DW10ATED4, RHW, RHM
# 024
25/08/08
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

- 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

# 024 - The tension is then adjusted to the final level, and the value is
25/08/08
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

Timing belt/kit installation on GM (Isuzu) 1.7D engines
GATES REFERENCE: 5563XS/K015563XS/K025563XS/K035563XS
MAKE: CHEVROLET, OPEL, VAUXHALL
MODEL: Astra, Combo, Corsa, Meriva, Tour, Zafira
ENGINE: Isuzu 1.7 DTI
ENGINE CODE: A17DT, A17DTR, Y17DT, Y17DTH,
# 025 Y17DTL, Z17DT, Z17DTH, Z17DTR
23/10/08
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

Main differences in composition and application:
+
K015563XS 5563XS I-> eng nr 328704
# 025
23/10/08
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.
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:

# 025 Engine must be cold.
Put engine at Top Dead Centre (TDC).
23/10/08
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 (non-
tensioner 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
Spring trapped behind tensioner
# 025 Serious
misalignment
23/10/08
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 (non-
tensioner 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.

** 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
# 025 the tensioner should be completely released and tensioning procedure
23/10/08 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

SOFIM 2.4 / 2.5 / 2.8 Diesel engines
GATES REFERENCE : 5039 (K01), 5113 (K01), 5334XS (K01), 5335XS
(K01), 5495XS (K01)
MAKE : Fiat / Iveco / Opel / PSA / Renault
MODEL : Various
ENGINE : 2.4 / 2.5 / 2.8 / D, TD, DTi, DTic, Dci, JTD, HDi
# 026 ENGINE CODE :

(all 8 valves)
Various
17/11/2008
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 Axle
plate
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.
Copyright © 2008 Gates Corporation 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

Abnormal rotation traces
Copyright © 2008 Gates Corporation

78 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
Visit our web catalogue www.gatesautocat.com
Caution
Use Gates products only on applications specified 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.
When it comes to power transmission products,
rely on Gates!
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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 www.gates.com/europe/technical
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E2 Technical Bulletin

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E2 Technical Bulletin

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E2/70503

If you wish to receive Gates Technical Bulletins by e-mail,

All technical bulletins are available at

Only install belt and tensioner when engine is at room temperature.

Technical Bulletin 001 Copyright © 2006 Gates Corporation Page 1 of 3

Rotating the tensioner in the wrong direction, having the Allen

Technical Bulletin 001

Technical Bulletin 001 Copyright © 2006 Gates Corporation Page 3 of 3

GATES REFERENCE : 5543XS and 5559XS

A lot of customers have problems finding this engine number (which

Up to the breakpoint some engines can be equipped with a plastic

- Never replace belt 5559XS by 5543XS !

Technical Bulletin 002 Copyright © 2006 Gates Corporation Page 1 of 1

GATES REFERENCE : 5571XS and 5572XS

# 003 4FD, 4GA, 4GC, 4GD, 4HA, S1

The new automatic tensioner/bolt can simply be installed in place of the

Technical Bulletin 003 Copyright © 2006 Gates Corporation Page 1 of 1

GATES REFERENCE : K025433XS

# 004 ZH14ASDA, ZH14FXDB, ZH14FXDC,

Technical Bulletin 004 Copyright © 2005 Gates Corporation Page 1 of 1

# 005 4FD, 4GA, 4GC, 4GD, 4HA, S1

The automatic tensioner can be mounted in place of the old (manual)

Ford Transit 2.5 D K015571XS/K015572XS

Only install belt and tensioner when engine is at room temperature.

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

6 Turn tensioner clockwise (with Allen key) until the checkmark is

Technical Bulletin 005 Copyright © 2006 Gates Corporation Page 1 of 2

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

Technical Bulletin 005

GATES REFERENCE : Micro-V XF belts – PJ profile

# 006 MOTOR CODE ::

Fig. 1: Electrically driven fan Fig. 2: PJ belt

In case additional cooling is needed (cars with air conditioning, with a

Technical Bulletin 006 Copyright © 2006 Gates Corporation Page 1 of 2

Technical Bulletin 006

Due to our drive to follow the OE market, we have introduced a new

Over the past years VAG made many changes on belt OE

* OE 028109119D/H/J/K/M all changed to 028109119P. Our

An updated OE/competitive cross list is also included in attached file (tab

Technical Bulletin 007 Copyright © 2006 Gates Corporation Page 1 of 1

# 008 MOTOR CODE : 52710, 852702, 852750, B210, J8S02, J8S240,

Our kits K015040/K025040 are no longer available, and have been

Technical Bulletin 008 Copyright © 2006 Gates Corporation Page 1 of 2

• K035040: belt 7700663544, tensioner 7700871169

Technical Bulletin 008

! Technical bulletin 009 is replaced with Technical bulletin 25 !

Technical Bulletin 009 Copyright © 2006 Gates Corporation Page 1 of 4

After durability problems it was decided to reengineer the synchronous

In order to cover the other 5% and to better serve our customers, we

Note: The old system is no longer available on OES level. It is strongly

Technical Bulletin 010 Copyright © 2006 Gates Corporation Page 1 of 4

Fig. 1 new system

Tensioner pulley differences

At first sight tensioner pulley 058109243D (fig. 3) used in K03/K045492XS

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