Removal and installation of a toothed belt (engine 1.6 l)

Timing gear drive

The timing belt must be removed when the engine is cold.

Withdrawal

1. Disconnect ground wire from battery.



2. Remove the toothed belt cover after releasing the 4 clips (indicated by arrows).

3. Disconnect the crankcase breather hose from the cylinder head cover.

4. Remove the cylinder block cover by first unscrewing 10 M10 bolts.



5. Turn the crankshaft to the TDC position of cylinder 1 using a 32 mm wrench. Turn the crankshaft pulley clockwise with a wrench. The crankshaft is in the TDC position if the groove on the end of the camshaft is parallel to the top plane of the cylinder head, with the larger semicircle at the top.


6. Loosen the toothed belt tensioner by loosening the Torx T50 bolt.

7. Remove toothed belt.

Attention! After removing the toothed belt, the crankshaft must not be rotated, as the pistons may collide with the open valves.

Installation

Dimensions of the mandrel for installing the crankshaft in the TDC position

1. For precise installation, it is necessary to use a mandrel to set the crankshaft to the TDC position (Ford fixture 21-104) and mounting bracket (Ford fixture 21-105) to fix the camshaft.



2. Insert a square or steel plate 5 mm thick into the groove of the camshaft. Turn the camshaft with the square until the square stops against the cylinder head. Use a feeler gauge to measure the gap on the other side of the square, between the square and the cylinder head. Insert a feeler gauge, the thickness of which is half the measured clearance, and turn the camshaft until the square stops against the feeler gauge. On the other side of the square, insert a second feeler gauge of the same thickness between the end of the square and the cylinder head.


3. Remove the camshaft sprocket bolt.

4. Release the pulley from the landing cone by hitting the back of the pulley with a mallet. The pulley must remain on the camshaft and be able to turn.



5. Unscrew the plug (indicated by the arrow in Figure A) on the engine block on the front side of the engine between the high pressure fuel pump and the generator and screw in a mandrel instead of the plug (figure B) to set the crankshaft to TDC.

6. Turn the crankshaft clockwise with a ring wrench until it stops in the mandrel, while accurately fixing the crankshaft.

7. Put a toothed belt on the pulleys.

8. Tighten the toothed belt using an 8mm hex wrench and turning it counterclockwise.



9. Tighten the belt tensioner to 30 Nm.


10. Tighten camshaft pulley to 30 Nm.

11. Check toothed belt tension.

12. Fit toothed belt guard and secure with 4 clips.

13. Unscrew the TDC mandrel and screw the plug back in instead.

14. Install the cylinder head cover with a new gasket and tighten the bolts evenly and crosswise.

15. Connect the crankcase ventilation hoses.

Installing the protractor on the fuel pump pulley

Checking the toothed belt tension

To check and adjust the tension of the toothed belt, you must have a protractor with a 360°scale and a device for checking the tension of the toothed belt (Ford 21-113).

1. Disconnect ground wire from battery.

2. Remove the toothed belt cover after releasing the 4 clips.

3. Install the protractor on the fuel pump pulley so that the mark on the pulley matches the 25°division on the protractor.

4. Rotate the crankshaft at least 90° (quarter turn) clockwise by turning the center bolt with a 32mm box wrench or by moving the vehicle in 4th gear.

5. Turn the crankshaft with a 32 mm ring wrench 25°counterclockwise.



6. Install the belt tension tester. The tension of the toothed belt is measured in the section of the belt between the fuel pump pulley and the camshaft pulley.


7. Lay the toothed belt between points A, B and C of the tool, while the tensioner must be between the teeth of the belt.

8. The tension of the toothed belt is correct if the readings of the device are from 8.5 to 10.5.

9. If the belt tension is not correct, adjust the toothed belt tension.

Toothed belt tension adjustment

1. Loosen the toothed belt tensioner by loosening the Torx T50 bolt.

2. Install the toothed belt tensioner.

3. Insert an 8mm hexagon wrench into the tensioner and, by turning it, adjust the tension of the toothed belt to the required value and tighten the Torx T50 bolt.

4. Recheck belt tension.

5. Check the injection timing of the fuel pump.

6. Remove the protractor.

7. Install toothed belt guard and secure with clips.