Attention. When replacing a timing belt, a new head cover gasket, some special tools, a tensioner spring, and a spring retaining pin are required.
Withdrawal
Remove the ground wire from the battery. Loosen the water pump pulley bolts.
Remove the cylinder head cover. Unscrew the spark plugs. Remove the auxiliary drive belt.
Set the #1 cylinder piston to TDC on the compression stroke. Unscrew the bolt and remove the water pump pulley and auxiliary drive belt idler pulley.
To fix the camshafts, it is necessary to use a Ford tool 21-162 or a metal strip 5 mm thick, 80-230 mm long and 20-30 mm wide. Check that the #1 cylinder piston is at TDC on the compression stroke, and slide a tool or plate into the groove on the left end of both camshafts. The tool should fit snugly into the grooves of the camshafts and rest on the mating surface of the cylinder head, if necessary, tighten the camshaft with a wrench to install the plate in the groove (see fig. 2C.12)
If both camshaft grooves are below the cylinder head mating surface, turn the crankshaft one full turn clockwise and install Ford tool 21-162.
After fixing the camshafts, remove the crankshaft pulley. Remove the bottom and middle timing belt covers.
Loosen the tensioner bolt, and using a wrench inserted in the center, turn the tensioner clockwise as far as possible and re-tighten the bolt to lock the tensioner away from the toothed belt (see fig. 2C.14). If the timing belt is to be reused, use white paint to mark the direction of rotation of the belt. Remove the toothed belt. Do not rotate the crankshaft until the timing belt is installed.
Check the condition of the belt and replace if necessary. Also check the tensioner spring and the condition of the pulleys
Installation
When installing, temporarily install the crankshaft pulley, check that the crankshaft pulley is in the position of cylinder No. 1 at TDC on the compression stroke, and both camshafts are fixed with a special tool. If the engine is reassembled after a major overhaul, both pulleys should turn freely on their respective camshafts, if the timing belt is just being replaced, both pulleys should still be secure.
To tighten the pulley bolts, a Ford 15-030A special tool is required to prevent the camshaft pulleys from turning, or make a suitable replacement tool.
Attention. Do not use a camshaft locking tool.
Install the timing belt tensioner by tightening the mounting bolts to the required torque (see fig. 2C.15, 2C.16).
In all cases, loosen the tensioner bolt and use the wrench inserted in the center to turn the tensioner clockwise as much as possible and re-tighten the bolt to secure the tensioner (see fig. 2C.17).
Install the timing belt first on the crankshaft pulley, then counterclockwise around the camshaft pulleys and tensioner, and finally on the rear pulley. The front branch of the belt between the crankshaft and the exhaust camshaft pulley must be tensioned without changing the position of the crankshaft or camshaft (ov). If necessary, the position of the camshaft pulleys can be changed by turning each pulley on the camshaft (which remains fixed with a special tool).
After installing the toothed belt, loosen the tensioner until the spring turns the tensioner, stretching the belt (see fig. 2C.18).
Tighten the camshaft pulley bolts (or make sure they are tight) and remove the camshaft locking tool. Temporarily install the crankshaft pulley, and rotate the crankshaft two full turns clockwise to tighten the toothed belt, returning the crankshaft to TDC. Install the tool that fixes the camshafts, while it should fit snugly into the grooves of the camshafts.
If one camshaft does not provide the installation of a fixing tool, unscrew the pulley mounting bolt and set the camshaft to the desired position. Rotate the crankshaft again two full turns clockwise, check the position of the camshafts by installing a special tool or a metal plate in the grooves.
If the camshaft is out of line, secure the pulley from turning and loosen the mounting bolt - the camshaft can be turned (gently and carefully when using a double ended wrench) until the camshaft locking tool is in place (see fig. 2С.19).
After installing the toothed belt and its correct tension, and installing a special tool or plate in the camshafts, check that the crankshaft pulley marks are exactly aligned, tighten the tensioner bolt to the required torque (see fig. 2С.20).
Further installation is carried out in the reverse order of removal.
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