Timing Belt: Installation

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Do not tighten the bolts. The camshaft timing pulleys must be able to turn freely on the camshafts.

Fig 1: Inserting Special Tool Into Camshafts

Courtesy of FORD MOTOR CO.

Turn the camshafts to the ignition position on cylinder No. 1 and insert the special tool into the camshafts.

NOTE: Only turn the engine in the normal direction of rotation.

1. Rotate the crankshaft to TDC on cylinder No. 1.
  
  Fig 2: Rotating Crankshaft To TDC On Cylinder No. 1
  Courtesy of FORD MOTOR CO.
Remove the blanking plug, install the special tool.

Fig 3: Removing Blanking Plug
Courtesy of FORD MOTOR CO.

CAUTION: Do not kink the timing belt (do not bend the timing belt less than a diameter of 35 mm).

CAUTION: Do not rotate the crankshaft, check that it is still resting against the timing pin.

NOTE: The lug of the belt tensioner must not be hooked into the sheet metal cover during timing belt installation.

Install a new timing belt.
- Starting from the crankshaft timing belt pulley and working counterclockwise install the timing belt, keeping it under tension.
  
  Fig 4: Installing New Timing Belt
  Courtesy of FORD MOTOR CO.

CAUTION: Incorrect timing belt tension will result in incorrect valve timing.

Pretension the timing belt.
1. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover.
2. Position the hexagonal key slot in the tensioner adjusting washer to the 4 o'clock position.
3. Tighten the attaching bolt enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 6 mm hexagonal key.
  
  Fig 5: Pretensioning Timing Belt
  Courtesy of FORD MOTOR CO.

CAUTION: Tension the timing belt, working counterclockwise.

Fig 6: Rotating Adjusting Washer Counterclockwise

Courtesy of FORD MOTOR CO.

Using the hexagonal key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment).
Tighten the bolt, while holding the adjusting washer in position.

Fig 7: Tightening Tensioner Bolt
Courtesy of FORD MOTOR CO.

NOTE: Use an open ended wrench to prevent the camshaft from rotating.

Fig 8: Tightening Camshaft Pulley Retaining Bolts

Courtesy of FORD MOTOR CO.

Tighten the camshaft pulley retaining bolts.

NOTE: Use an open ended wrench to prevent the camshaft from rotating.

Fig 9: Installing Intake Camshaft Pulley Blanking Plug

Courtesy of FORD MOTOR CO.

Install the intake camshaft pulley blanking plug.
Remove the special tool.

Fig 10: Removing Special Tool
Courtesy of FORD MOTOR CO.
Remove the special tool from the camshafts.

NOTE: Turn the crankshaft two revolutions in the normal direction of rotation.

Check the valve timing by inserting the special tool. Correct it if necessary.
- Install the special tool and make sure that the it is contact with the crankshaft.
- Install the special tool into the camshafts; if necessary loosen the timing pulleys and correct the camshaft alignment.
- Remove the special tools.
Install the special tool.

Fig 11: Installing Special Tool
Courtesy of FORD MOTOR CO.

CAUTION: Use a blunt object (a plastic cable tie) to apply the silicone grease, to avoid damaging the spark plug connectors.

CAUTION: Push on the spark plug connectors, keeping them in line with the spark plugs.

NOTE: Coat the inside of the spark plug connectors with silicone grease to a depth of 5-10 mm.

Install the valve cover.
1. Tighten the bolts in two stages.
  - Stage 1: 2 Nm.
  - Stage 2: 7 Nm.
2. Attach the PCV hose to the valve cover.
  - Connect the VCT actuator electrical connector.
3. Coat the spark plug thread with anti-seize grease, screw in the spark plugs and push in the spark plug connector until it engages.
  
  Fig 12: Installing Valve Cover
  Courtesy of FORD MOTOR CO.
Install the spark plug cover.

Fig 13: Installing Spark Plug Cover
Courtesy of FORD MOTOR CO.

NOTE: Position the upper timing belt cover and the center timing belt.

Fig 14: Installing Engine Front Mount Bracket

Courtesy of FORD MOTOR CO.

Install the engine front mount bracket.

NOTE: Check the seating of the timing belt upper cover gasket and correct as necessary.

Fig 15: Attaching Timing Belt Upper Cover

Courtesy of FORD MOTOR CO.

Attach the timing belt upper cover.
Install the engine front mount.

Fig 16: Installing Engine Front Mount
Courtesy of FORD MOTOR CO.
Attach the power steering pump fluid reservoir.

Fig 17: Attaching Power Steering Pump Fluid Reservoir
Courtesy of FORD MOTOR CO.
Attach the coolant expansion tank.

Fig 18: Attaching Coolant Expansion Tank
Courtesy of FORD MOTOR CO.
Remove the trolley jack and wooden block.
Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
Attach the lower timing belt cover.

Fig 19: Attaching Lower Timing Belt Cover
Courtesy of FORD MOTOR CO.
Install the crankshaft pulley.

Fig 20: Installing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
Install the blanking plug.

Fig 21: Installing Blanking Plug
Courtesy of FORD MOTOR CO.

NOTE: Direction of travel on a used drive belt. Install the drive belt.

1. Attach the multi-groove belt idler pulley.
  - Attach the coolant pump pulley. Do not tighten the bolts at this stage.
2. Install the drive belt by turning clockwise and tension it.
3. Tighten the bolts on the coolant pump pulley.
  
  Fig 22: Installing Drive Belt
  Courtesy of FORD MOTOR CO.
Lower the vehicle.
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .