Timing belt — removal and installation (Power unit / Engine 1.4/1.6 Zetec-SE / Ford Focus 1 1998-2004)

Special tool

	Universal wrench for holding flanges 205-072 (15030A)
	Goniometer 303-174 (21540)
	Camshaft Alignment Tool 303-376 (21162B)
	Spark Plug Wrench 303-499 (21202)
	Pin for setting the top dead center of the crankshaft 303-507 (21210)
	Pliers for spark plug connectors 303-622 (21226)

General equipment: Rolling jack.

Name	Specification
clamps
Lubricant (for threading spark plugs - Never Seeze)	ESE-M1244-A
Silicone Grease	ESE-M1C171-AA

Withdrawal

All cars

1. Disconnect a wire of weight from the accumulator. See Section 414-01 for more information.

2. Loosen the bolts on the water pump pulley.

3. Raise the vehicle. See Section 100-02 for more information.

4. Remove the drive belt cover.

5. Loosen the drive belt and remove it.

6. Remove pulley/damper from crankshaft.

1.Install the special tool using two bolts: M10x40 and M10x45 - and nuts.
2. Remove the bolt.
Lock against rotation using the special tool.

7. Remove the coolant pump pulley and drive belt idler pulley.

8. Remove the bolts from the timing belt cover.

1.Top timing belt cover
2.Lower timing belt cover
Remove the bottom cover.

9. Lower the car.

10. Remove the cylinder head cover plate (in the presence of).

1. Release the fuel lines.
2.Disconnect the crankcase ventilation hose.
3.Release the carbon filter vacuum line bracket.
4.Remove the bolts (six bolts).

11.

CAUTION: When disconnecting the spark plug connector, do not pull on the wire. If necessary, remove the ignition coil to avoid bending the wire. To release the gasket, turn the spark plug connector slightly before removing.

CAUTION: Disconnect the spark plug connector using straight line force only.

CAUTION: Do not damage the cylinder head cover gasket as it cannot be replaced separately.

Remove the cylinder head cover by moving it straight up.

1. Disconnect the plug connector of the cylinder head temperature sensor (SNT).
Release the clip on the CHT sensor's plug connector.
2. Disconnect the high voltage wires from the spark plugs.
For angled spark plug connectors, use special tool 303-622.
3. Turn out three bolts from the top cover of a timing belt.
4. Loosen and remove the nuts.

12. Remove the spark plugs. Use a special tool to remove.

13. Disconnect the expansion tank of the cooling system.

1. Remove the bolt.
2. Release the expansion tank of the cooling system and place it aside.

14. Release the power steering reservoir and set it aside.

15. Remove the generator and place it aside.

1.Disconnect the plug connector.
2.Disconnect the positive wire.
3. Disconnect the generator.
Disconnect the pins.

16. Place a rolling jack with wooden blocks under the oil sump and raise it slightly so as to unload the front engine mount.

17. Remove the engine support.

18. Remove the top timing belt cover.

19. Remove the front engine mount bracket (shown on removed engine).

Timing belt tensioner with eccentric

20.

NOTE: If the timing belt is to be reused, note the direction of travel.

Loosen the tension and remove the timing belt (shown with engine removed). Turn out a bolt.

Groove Timing Belt Tensioner

21.

NOTE: When reusing the timing belt, note the direction of travel.

Loosen the tension and remove the timing belt (shown with engine removed). Turn out bolts.

Installation

All cars

1. Set the crankshaft to 20 degrees before top dead center.

2.

CAUTION: Use a special tool to prevent them from turning.

Loosen the bolts just enough to allow the camshaft pulleys to turn on the shafts.

3. Rotate the camshafts to the top position for cylinder #1 and insert the special tool. Turn the camshafts at the hex shank using a 21mm double end wrench just enough to insert the special tool.

NOTE: Note the direction of travel.

Put on the timing belt. Starting at the crankshaft pulley and working in a counterclockwise direction, slide the timing belt into place.

5. Connect the lower timing belt cover (shown from below).

NOTE: Use a new bolt.

Install the pulley/damper onto the crankshaft.

Tighten the bolt, working in two steps.
Stage 1: 40 Nm
Stage 2 (using special tool 303-174): 90 degrees

NOTE: If it is not possible to insert the special tool, rotate the crankshaft back counterclockwise approximately 20 degrees.

Rotate the crankshaft to top dead center for cylinder #1.

Remove the plug and screw in the special tool.
Carefully turn the crankshaft in a clockwise direction until it rests against the special tool.

Timing belt tensioner with cam

8.

NOTE: Do not move the eccentric when tightening. Hold using a socket wrench.

Tension the timing belt (shown with engine removed).

Using a 6mm socket wrench, turn the eccentric in a counterclockwise direction until the pointer needle is exactly in the center of the rectangular hole.
Tighten the bolt.

Groove Timing Belt Tensioner

9. Tighten the timing belt (shown with engine removed).

Using a socket wrench, turn the tensioner so that the arrow aligns exactly with the center of the rectangular hole.
Tighten the bolts.

10.

CAUTION: Do not tighten the camshaft pulley while holding the camshaft from turning with special tool 303-376.

NOTE: Do not rotate the crankshaft and camshafts.

Tighten the bolts on the camshaft pulleys.

11. Remove special tool 303-376.

12. Unscrew the special tool (shown from below).

13. Check the valve timing.

Rotate the crankshaft two turns clockwise and bring cylinder #1 to top dead center.

NOTE: If special tool 303-507 cannot be installed, rotate the crankshaft back counterclockwise approximately 20 degrees.

Screw in special tool 303-507.
Carefully rotate the crankshaft in a clockwise direction until it rests against the special tool 303-507.

14. Check the valve timing by installing a special tool.

15.

NOTE: Only if special tool 303-376 cannot be inserted.

NOTE: Hold using the special tool.

NOTE: The crankshaft must remain at top dead center for cylinder #1.

Adjust the valve timing.

Loosen the bolt of the camshaft in question.
Turn the camshaft at the hexagon until the special tool 303-276 can be inserted.
Tighten the pulley on the camshaft.
Check the valve timing again as previously described.

16. Install the spark plugs, use the special tool. Apply lubricant to the threads of the spark plugs.

17. Install the front engine mount bracket.

18. Reinstall the timing belt top cover.

19. Install the engine mount.

20. Remove the rolling jack.

21. Install the generator.

1.Connect the connector.
2. Connect the positive wire.
Install the studs.
3.Install the generator.

22. Raise the vehicle. See Section 100-02 for more information.

23. Remove special tool 303-507 and screw in plug.

24. Establish bolts of the top covers of a timing belt.

25. Install the water pump pulley and drive belt idler pulley.

26. Put on and tension the drive belt.

27. Install the drive belt cover.

28. Lower the car.

29. Fix a reservoir of the amplifier of a steering.

30. Connect a broad tank of system of cooling.

1.Fix the expansion tank.
2.Tighten the bolt.

31.

CAUTION: To avoid damage to the spark plug connector seal, use a blunt object to apply silicone grease (e.g. plastic clamp).

CAUTION: Attach the spark plug connector using a straight line force.

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

Install the cylinder head cover.

1.Install nuts and tighten, working in two steps. Stage 1: 3 Nm. Stage 2: 10 Nm.
2. Connect the plug connector of the SNT sensor.
3. Connect the spark plug connector.
4.Install the three bolts of the upper timing belt cover.

32. Install the cylinder head cover plate (if it was taken).

1. Screw in the bolts (six bolts).
2. Connect the PCV hose.
3.Fix the carbon filter vacuum line bracket.
4.Fix the fuel lines.

33. Standard final operations:

Connect ground wire to battery. See Section 414-01 for more information.
If necessary, secure the wires using cable ties.

Timing belt — removal and installation

Special tool

Withdrawal

Installation

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