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Timing Drive Components: Removal

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.
CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.
  1. With the vehicle in NEUTRAL, position it on a hoist.
  2. Remove the fan shroud. For additional information, refer to ENGINE COOLING .
  3. Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
  4. Remove the valve cover. For additional information, refer to VALVE COVER .
  5. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
  6. Remove the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  7. Remove the bolts and the battery tray.
    Fig 1: Removing Battery Tray Bolts
    G01611363Courtesy of FORD MOTOR CO.
  8. Release the wiring harness.
    1. Remove the nuts retaining the wiring harness.
    2. Release the wiring harness retainers from the timing cover studs.
      Fig 2: Releasing Wiring Harness Retainers From Timing Cover Studs
      G01611364Courtesy of FORD MOTOR CO.
    9. NOTE: If the crankshaft position (CKP) sensor is damaged during engine front cover removal a new CKP sensor must be installed. Refer to the manufacturer instructions for sensor installation.
    Fig 3: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector
    G01611365Courtesy of FORD MOTOR CO.
  9. Disconnect the crankshaft position (CKP) sensor electrical connector.
    10. CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
    CAUTION: The special tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshaft.
    Fig 4: Installing Special Tool In Slots On Rear Of Both Camshafts
    G01611366Courtesy of FORD MOTOR CO.
  10. Using the crankshaft pulley bolt, turn the crankshaft clockwise and position the No. 1 piston at TDC. Install the special tool in the slots on the rear of both camshafts.
  11. Remove the plug bolt.
    Fig 5: Removing Plug Bolt
    G01611367Courtesy of FORD MOTOR CO.
    12. NOTE: After the No. 1 piston is set in the TDC position and the Timing Peg is installed, the Timing Peg will stop the engine from turning in a clockwise direction.
    Fig 6: Installing Special Tool (303-507)
    G01611368Courtesy of FORD MOTOR CO.
  12. Install the special tool.
  13. Install the special tool.
    Fig 7: Installing Special Tool (303-F072)
    G01611369Courtesy of FORD MOTOR CO.
  14. Remove the LH motor mount center nut.
    Fig 8: Removing LH Motor Mount Center Nut
    G01611370Courtesy of FORD MOTOR CO.
  15. Remove the RH motor mount. For additional information, refer to ENGINE MOUNT-RH .
  16. Loosen the lower engine mount nuts.
    Fig 9: Loosening Lower Engine Mount Nuts
    G01611371Courtesy of FORD MOTOR CO.
  17. Lower the engine enough to allow for the clearance to install special tools.
    18. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
    Fig 10: Installing Bolt Through Crankshaft Pulley And Thread Into Front Cover
    G01611372Courtesy of FORD MOTOR CO.
  18. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover. Rotate the pulley as necessary to align the bolt holes.
  19. Install the special tools.
    Fig 11: Installing Special Tools (205-126)
    G01611373Courtesy of FORD MOTOR CO.
    20. CAUTION: Failure to hold the crankshaft pulley in place during bolt loosening can result in damage to the engine.
  20. Remove the bolt and the crankshaft pulley.
    1. Remove the crankshaft bolt.
    2. Remove the special tools.
    3. Remove the 6 mm (0.23 in) bolt.
    4. Remove the crankshaft pulley.
      Fig 12: Removing Crankshaft Pulley
      G01611374Courtesy of FORD MOTOR CO.
  21. Remove the accessory drive belt tensioner.
    1. Remove the bolts.
    2. Remove the tensioner.
      Fig 13: Removing Accessory Drive Belt Tensioner
      G01611375Courtesy of FORD MOTOR CO.
  22. Disconnect the power steering pressure (PSP) switch electrical connector.
    Fig 14: Disconnecting Power Steering Pressure (PSP) Switch Electrical Connector
    G01611376Courtesy of FORD MOTOR CO.
  23. Remove the nut and detach the PSP tube bracket.
    Fig 15: Removing Nut And Detach PSP Tube Bracket
    G01611377Courtesy of FORD MOTOR CO.
  24. Disconnect the PSP tube.
    • Remove and discard the Teflon O-ring seal.
      Fig 16: Removing Teflon O-Ring Seal
      G01611378Courtesy of FORD MOTOR CO.
  25. Remove the four bolts and position the power steering pump aside.
    Fig 17: Removing Power Steering Pump Bolts
    G01611379Courtesy of FORD MOTOR CO.
  26. Remove the coolant pump pulley.
    Fig 18: Removing Coolant Pump Pulley
    G01611380Courtesy of FORD MOTOR CO.
  27. Remove the accessory drive belt idler pulley.
    Fig 19: Removing Accessory Drive Belt Idler Pulley
    G01611381Courtesy of FORD MOTOR CO.
    28. CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
  28. Inspect the crankshaft front oil seal for wear or damage.
    • If necessary, remove the crankshaft front oil seal using the special tool.
      Fig 20: Removing Crankshaft Front Oil Seal
      G01611382Courtesy of FORD MOTOR CO.
  29. Remove the bolts and the engine front cover.
    Fig 21: Removing Engine Front Cover Bolts
    G01611383Courtesy of FORD MOTOR CO.
  30. Remove the timing chain tensioner.
    1. Compress the timing chain tensioner, and insert a paper clip into the hole to retain the tensioner.
    2. Remove the bolts and timing chain tensioner.
      Fig 22: Removing Timing Chain Tensioner
      G01611384Courtesy of FORD MOTOR CO.
  31. Remove the RH timing chain guide.
    Fig 23: Removing RH Timing Chain Guide
    G01611385Courtesy of FORD MOTOR CO.
  32. Remove the timing chain.
    Fig 24: Removing Timing Chain
    G01611386Courtesy of FORD MOTOR CO.
  33. Remove the bolts and the LH timing chain guide.
    Fig 25: Removing LH Timing Chain Guide Bolts
    G01611387Courtesy of FORD MOTOR CO.
    34. CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
  34. If necessary, remove the bolts and the camshaft sprockets.
    • Use the flats on the camshaft to prevent camshaft rotation.
      Fig 26: Removing Camshaft Sprockets Bolts
      G01611388Courtesy of FORD MOTOR CO.
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