Timing Belt — Removal and Installation

Special tool

	Universal Flange Holding Wrench 205-072 (15-030A)
	Crankshaft Top Dead Center Pin 303-193 (21-104)
	Engine Support Beam 303-290A (21-140A)
	Adapter for 303-290A (21-140) 303-290-01 (21-140-01)
	Adapter for 303-290A (21-140) 303-290-02 (21-140-02)
	Adapter for 303-290A (21-140) 303-290-03A (21-140-03A)
	Camshaft Alignment Plate 303-376 (21-162B)
	Flywheel Locking Tool 303-393 (21-168)
	Camshaft Sprocket Puller 303-651 (21-229)

Name	Specification
Coolant	ESDM-97B49-A
Motor oil	WSS-M2C912-A1

Removal

All cars

1.

CAUTION: Never install a used timing belt.

CAUTION: Install the timing belt only after the engine has cooled to outside temperature.

Disconnect the ground cable from the battery. For additional information, refer to Section 414-01.

2. Remove the cylinder head cover. For more information, refer to the Cylinder Head Cover chapter in this section.

3. Disconnect the expansion tank of the cooling system and place it aside.



4. Remove the charge air cooler cover.




5. Disconnect the intake air temperature (IAT) sensor connector.



6. Remove the charge air cooler.



7. Disconnect the power steering pipe mounting bracket from the cylinder head.



8. Using the groove in the camshaft as a guide, rotate the crankshaft to a position five degrees before top dead center (TDC).




9. Remove the accessory drive belt. For additional information, refer to Section 303-05.

10. Remove the generator coupling.

• 1. Bolts for fastening the intermediate axle bearing.
• 2. Vibration damper mounting bolts.

11. Disconnect the starter and place it aside.



12. Install the special tool. Remove the plug from the cylinder block and install the special tool.




13.

NOTE: The crankshaft must be turned in the normal direction of rotation.

Turn the crankshaft to the top dead center position. Slowly turn the crankshaft until it stops.

14.

CAUTION: Do not turn the crankshaft while installing the special tool.

CAUTION: Before locking the special tool, make sure the crankshaft is at top dead center (TDC).

CAUTION: Make sure the special tool is installed correctly.

Using a special tool, lock the crankshaft.



15. Lower the vehicle.

16. Install special tools.



Cars manufactured up to 04.2001.


17. Remove the front engine mount.



Cars manufactured since 04.2001.

18. Remove the front engine mount.



All cars

19. Remove the front engine mount stud.



20. Remove the timing belt cover.



21. Install the special tool.



22. Remove the timing belt tensioner.



Engines with mechanical timing belt tensioner

23. Discard the timing belt tensioner as it is no longer needed.

All cars

24. Remove the timing belt and discard it as it is no longer needed.

25. Using the special tool, loosen the camshaft pulley mounting bolt by five turns.



26. Using the special tool, release the camshaft pulley.

Installation

All cars

1.

NOTE: Only the latest type timing belts should be installed. They can be identified by the laser etched Ford emblem.

Check the new timing belt.



Engines with mechanical timing belt tensioner

2. Install the new automatic timing belt tensioner.

All cars

3. Check the automatic timing belt tensioner.

• 1.Make sure the tensioner arrow turns freely clockwise.
• 2. The arrow shows the rotation of the tensioner counterclockwise.

4.

NOTE: Move the timing belt tensioner adjustment lever to the 3 o'clock position.

Install the timing belt tensioner and tighten the bolt finger tight.



5.

CAUTION: Never install a used timing belt.

CAUTION: Install the timing belt so that the arrows point in the direction of engine rotation.

CAUTION: Install the timing belt only after the engine has cooled to outside temperature.

NOTE: Install a new timing belt.

Install the timing belt.

6.

NOTE: The camshaft pulley must be able to rotate freely on the camshaft taper.

Tighten the camshaft pulley bolt finger tight and then loosen it 1/2 turn.



7.

NOTE: Using a socket wrench, maintain tension until the tensioner bolt is tightened.

Tighten the timing belt.

• 1. Turn the timing belt tensioner adjusting lever counterclockwise to slightly tighten the timing belt.
• 2. The arrow should be located between the sides of the window.
• 3. Tighten the timing belt tensioner mounting bolt.

8. Using the special tool, tighten the camshaft pulley mounting bolt.



9. Remove the special tool.



10. Raise and support the vehicle. Refer to Section 100-02 for additional information.

11. Release the special tool.



12. Remove the special tool.



13.

NOTE: The crankshaft must be turned in the normal direction of rotation.

NOTE: Using paint or typing correction fluid, mark the crankshaft pulley to show top dead center (TDC).

Turn the crankshaft six revolutions.



14. Install the special tool.



15.

NOTE: The crankshaft must be turned in the normal direction of rotation.

Turn the crankshaft to the top dead center position. Slowly turn the crankshaft until it stops.

16.

CAUTION: Do not turn the crankshaft while installing the special tool.

CAUTION: Before locking the special tool, make sure the crankshaft is at top dead center (TDC).

CAUTION: Make sure the special tool is installed correctly.

Using a special tool, lock the crankshaft.



17. Lower the vehicle.

18.

NOTE: The automatic tensioner needle may move slightly up in the window.

Make sure the automatic tensioner arrow is positioned between the sides of the window.

• 1.If the pointer arrow is in the window, go to the next step.
• 2. If the pointer arrow is not in the window, repeat the procedure starting from the previous steps.

19. Install the special tool. If the special tool cannot be installed, repeat the procedure from the previous steps.



20. Remove the special tools.
21.

CAUTION: Do not damage the timing belt cover.

NOTE: Modification of the timing belt cover is only required if a mechanical timing belt tensioner was installed.

Using a suitable file, file down the timing belt cover.



22. Install the timing belt cover.



23. Install the front engine mount stud.



Cars manufactured up to 04.2001.

24. Install the front engine mount.



Cars manufactured since 04.2001.

25. Install the front engine mount.



All cars

26. Remove the special tools.



27. Raise and support the vehicle. Refer to Section 100-02 for additional information.

28. Remove the special tool and install the plug.



29. Connect the starter.



30. Install the generator coupling.



31. Install the accessory drive belt. Refer to Section 303-05 for additional information.

32. Connect the power steering pipe mounting bracket to the cylinder head.



33. Install the charge air cooler.



34. Connect the intake air temperature (IAT) sensor connector.



35. Install the charge air cooler cover.



36. Install the expansion tank of the cooling system.



37. Install the cylinder head cover. For more information, refer to the Cylinder Head Cover chapter in this section.

38. Connect the battery ground cable. Refer to Section 414-01 for additional information.