Timing belt — removal and installation (Power unit / Engine 1.6/1.8/2.0 Zetec-E / Ford Focus 1 1998-2004)

Special tool

	Universal wrench for holding flanges 205-072 (15030A)
	Camshaft Top Dead Center Setting Tool 303-376 (21-162V)
	Radiator hose clamp remover and installer 303-397 (24-003)
	Pin for setting the top dead center of the crankshaft 303-620 (21-163)
	Pliers for spark plug connectors 303-622 (21-226)

General equipment:

rolling jack
wooden block

Name	Specification
Never Seeze	ESE-M1244-A
clamps
Silicone grease for spark plug connector seals	A960-M1C171-AA
sealant	WSK-M2G348-A5

Withdrawal

All cars

1. General instructions:

The position of the engine mounts and engine roll limiters in the description corresponds to the view from the gearbox towards the engine.
If necessary, use special tool 303-397 to remove coolant and vent hoses.
Due to the different variants of one vehicle model, some operating steps are not applicable to all vehicles. In this case, this is clearly stated in the text.
If necessary, cut the clamps and replace them during installation.

2. Standard preparatory activities:

Note the radio key code.
Check the preset radio stations.

CAUTION: Disconnect the ground wire from the battery.

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

4. Disconnect the drive belt cover.

NOTE: Note the direction of travel of the drive belt.

Remove the drive belt.

1. Loosen the bolts on the water pump pulley.
2. Loosen the drive belt by turning it clockwise and remove it.
Disconnect the water pump pulley.
3. Disconnect the intermediate pulley of the V-ribbed belt.

6. Disconnect the crankshaft pulley/damper.

CAUTION: To prevent damage to the timing belt, always remove the timing belt cover.

Remove the lower timing belt cover.

8. Lower the car.

9. Disconnect the coolant expansion tank and set it aside.

10. Remove the PAS reservoir and set it aside.

11.

CAUTION: Insert a wooden block between the oil sump and the rolling jack.

Locate a rolling jack with a block of wood under the oil pan and lift up to take the load off the front engine mount.

12.

NOTE: Mark the position of the engine mount.

Remove the front engine mount.

13. Disconnect the upper timing belt cover. Leave the timing belt cover in its installation position.

14. Disconnect the center timing belt cover/front engine mount bracket. Remove the upper timing belt cover.

Cars with LPG mode

15. Remove the LPG fuel manifold. See Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G for more information.

All cars

16.

NOTE: Release sequence: from outside to inside, working in a cross way.

Remove the cylinder head cover.

CAUTION: When disconnecting the spark plug connector, do not pull on the wire. If necessary, disconnect the ignition wires from the ignition coil to avoid twisting the ignition wires. Before disconnecting the spark plug connector, turn it slightly to loosen the seal.

CAUTION: When disconnecting the spark plug connector, apply force on the axis of the spark plug (for angled spark plug connectors, use special tool 303-622).

1. Disconnect the spark plug connector.
2.Disconnect the PCV hose.
3. Turn out ten bolts.

17.

CAUTION: To adjust the valve timing, the spark plugs must be removed.

Remove spark plugs.

18. Rotate the crankshaft to top dead center. Insert special tool.

19. Loosen the timing belt tension.

1. Release the bolt and timing belt tensioner by turning the latter clockwise.
2. Remove the bolt four turns and unhook the timing belt tensioner.
Remove the timing belt.

Installation

All cars

1.

CAUTION: Use a new timing belt.

CAUTION: Do not tighten the camshaft pulley bolts using special tool 21-162B to lock the camshaft; use special tool 15-030A to prevent the shaft from turning.

NOTE: The camshaft pulleys must be able to rotate on the camshafts.

Release the camshaft pulleys.

2. Set the crankshaft to top dead center for cylinder #1.

3. Remove the plug and fully screw in the special tool.

CAUTION: Do not twist the timing belt (bend diameter should not be less than 35 mm).

CAUTION: Do not rotate the crankshaft. If necessary, check that the crankshaft rests against the special tool 303-620.

Install a new timing belt (shown on removed engine). Slide the timing belt back into place, starting at the crankshaft pulley and working counterclockwise. Tighten the belt as you put it on.

CAUTION: Do not rotate the crankshaft. If necessary, check that the crankshaft rests against the special tool 303-620.

NOTE: Design shown without lower idler pulley (manufactured starting around 01.99.).

NOTE: The timing belt tensioner clip must not be locked into the stamped steel cover.

Install a new timing belt (shown on removed engine). Slide the timing belt back into place, starting at the crankshaft pulley and working counterclockwise. Tighten the belt as you put it on.

CAUTION: If the timing belt tension is incorrect, the valve timing will also be incorrect.

NOTE: Tighten the timing belt by turning it counterclockwise.

Tension the timing belt.

1. Fix the belt tensioner in the stamped steel cover and screw in the bolt, but do not tighten it.
2.Tighten the timing belt by turning the tensioner counterclockwise so that the arrow lines up with the mark and tighten the bolt.

CAUTION: Do not tighten the camshaft pulley bolts using special tool 303-376 to lock the camshaft; use special tool 205-072 to prevent the shaft from turning.

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

Tighten the camshaft pulley bolts.

8. Unscrew and remove special tool 303-620.

9. Remove the special tool 303-376 from the camshafts.

10.

NOTE: Rotate the crankshaft two turns in the direction of normal rotation.

Check the valve timing by installing a special tool. Correct them if necessary.

Screw in the special tool 303-620 and make sure that the crankshaft rests against it.
Insert the special tool 303-376 into the camshafts; if necessary, release the pulleys and correct the alignment of the camshafts.
Disconnect special tools.

11. Screw in and tighten the plug.

12. Apply sealant to the camshaft bearing caps.

13. Install the cylinder head cover and spark plugs.

1. Tighten the bolts, working in two steps.
Stage 1: 2 Nm
Stage 2: 7 Nm
2. Connect the PCV hose.

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

CAUTION: When mating the spark plug connector, keep it in line with the spark plugs.

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

3. Apply Never Seeze to the spark plug threads, screw in the spark plugs and fully mate the spark plug connectors.

Cars with LPG mode

14. Install the LPG fuel manifold. See Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G for more information.

All cars

15.

NOTE: Reinstall the upper timing belt cover with the center timing belt cover.

Connect the timing belt center cover/front engine mount bracket.

16.

NOTE: Check the fit of the timing belt top cover gasket and adjust if necessary.

Install the timing belt top cover.

17. Install the front engine mount.

18. Connect the PAS tank.

19. Install the expansion tank of the cooling system.

20. Pull out the rolling jack towards the front of the vehicle.

21. Raise the car. See Section 100-02 for more information.

22. Install the lower timing belt cover.

23. Install the crankshaft pulley/damper.

24.

NOTE: Direction of travel on used drive belt.

Install the drive belt.

1.Install the intermediate pulley of the V-ribbed belt.

NOTE: Screw in the bolts just enough to hold, but do not overtighten.

Install the water pump pulley.
2.Put on the drive belt by moving it clockwise and tension it.
3. Tighten the bolts on the water pump pulley.

25. Install the drive belt cover.

26. Lower the car.

27. Standard final operations:

Connect ground wire to battery.
Check fluid levels and correct if necessary.
Check the wiring of vacuum hoses, cables and wires and secure them using clamps.
Enter the radio key code.
Reprogram preset radios.
Set your clock.
Carry out a road test to give PCM a chance to collect data.

Timing belt — removal and installation

Special tool

Withdrawal

Installation

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