Timing belt of the timing mechanism (Mondeo 1 and 2)

Note: This procedure requires a new belt (if necessary), a new cylinder head gasket, and special tools (see text). On pre-1998 models, if the belt is being removed for the first time since leaving the factory, purchase a tensioner spring and lock pin to install during reassembly.

Removal

1. Disconnect the negative battery cable (Chapter 5, paragraph 1). Apply the parking brake, raise the front of the vehicle and support it on stands. Remove the right front wheel and the mudguard from under the right fender. The timing belt drive components for models produced before 05/1998 are shown in Fig. 10.1.



2. Remove the power steering pressure line mounting bolts that secure it to the engine lifting eye/cylinder head rear support plate and to the pump bracket/front support plate.



3. Remove the six nuts securing the right engine/transmission mount bracket, then remove the bracket. On later models, remove the coolant expansion tank bolts and move it to the side without disconnecting the hoses. One of the engine mount bolts also secures the hose bracket (see Fig. 10.3, a, b).







4. Loosen the coolant pump pulley bolts.



5. Remove the cylinder head cover (section 5) (see Fig. 10.5).

6. Remove the spark plugs. Plug their holes with clean rags to prevent dirt from getting in (chapter 1).

7. Remove the accessory drive belt (Chapter 1).

8. Turn the crankshaft clockwise so that the second pair of marks on the pulley rim aligns with the edge of the sump mark. In this case, cylinders No.1 and 4 should be at TDC (paragraph 4).

9. Remove the bolts and the coolant pump pulley and the auxiliary drive belt idler pulley.

10. Purchase a special device (Ford 21-162) or make your own. It should be a corner with ends 5 mm thick, 20-30 mm wide and 180-230 mm long (the thickness of the plate is important, and the width and length are approximate). Make sure that cylinders No.1 and 4 are at TDC. cylinder No.1 in the compression stroke. To do this, install the above-described device on the surface of the cylinder head that is mated with its cover and push the device into the slots of both camshafts located on their left ends (see Fig. 10.10). The device should fit tightly but easily into both slots, adjoining the surface of the cylinder head joint. If one of the camshafts is slightly offset from this position, then it is permissible to carefully turn the camshaft with a wrench until it is aligned with the device.



11. If the slots of both camshafts (which are made below the shaft axes) are located below the level of the joint surface of the cylinder head, turn the crankshaft one full turn clockwise. Then reinstall the locking device. Now it should enter the slots (see item 10).



12. Keeping the locking device in this position, remove the crankshaft pulley. To prevent it from turning, do not lock the camshafts. To do this, proceed as described in paragraph 8.

13. Remove the lower and middle timing belt covers (paragraph 9).

14. Maintaining the position of the locking device, loosen the tensioner bolt and, inserting an Allen key into its center, turn the tensioner clockwise (models produced before 10/1996) or counterclockwise (models produced from 10/1996 to 05/1998) as far away from the belt as possible. Retighten the bolt to secure the tensioner away from the belt (see Fig. 10.14, a, b). On models produced from 05/1998, unscrew the tensioner bolt by 4 turns and remove the tensioner from the support plate.





15. If the timing belt is to be used again, mark the direction of rotation of the belt with white paint (or something similar) and also note which side it is installed on, paying attention to the manufacturer's markings. Remove the belt (see Fig. 10.15). Do not turn the crankshaft until the belt is reinstalled.





16. If you have removed the belt for reasons other than a scheduled replacement, carefully inspect it for uneven wear, cracks (especially at the base of the teeth), or contamination with oil or coolant. If you are in doubt about the serviceability of the belt, be sure to replace it. For safety reasons, the belt must be replaced according to the schedule (chapter 1). If you do not know the conditions under which the belt was used, it must be replaced regardless of its condition during engine repair. Similarly, check the tensioner spring (if any) and replace it if you doubt its serviceability. Also check the toothed pulleys for wear or damage. Make sure that the guide pulleys and the tensioner pulley rotate smoothly in their bearings. Replace worn or damaged components. If contamination with oil or coolant is detected, identify the source of the leak and eliminate it. Then wash the surface of the engine and components in the belt area to remove traces of oil or coolant.

Installation and adjustment

17. When installing, temporarily fit the crankshaft pulley to check the alignment of the pulley marks and the sump mark (as indicated in step 8). Then, using a locking device, check the installation of the camshafts in the position corresponding to TDC (step 10). If you are assembling the engine after its complete disassembly, the pulleys of both camshafts should rotate freely relative to the shafts. If you are only replacing the belt, both pulleys should be secured to the shafts during the procedure.



18. To prevent the camshaft pulleys from turning when loosening and tightening their bolts, you will need a special device. This can be a branded device (Ford 15-030 A) or a homemade one. To make it, you will need two steel strips 600 and 200 mm long and three bolts with nuts and washers (see Fig. 10.25). The ends of the strips are connected by a hinge (bolt, nut and washer), and each of the remaining ends of the strips also has a bolt, nut and washer.

Note: Do not use a TDC setting device to lock the camshafts due to the risk of damaging the corresponding camshaft and cylinder head. Use only a scissors-type device, installing it directly on the pulleys.

19. If the belt is being installed for the first time (on models manufactured before 05.1998), screw the timing belt tensioner spring locking pin into the cylinder head and tighten it to the specified torque. Unscrew the tensioner bolt, place the spring on the pin and the tensioner rear cover. Then install the tensioner, aligning its rear cover with the installation lug (see Fig. 10.19, a-c). In any case, loosen the tensioner bolt (if necessary) and, using an Allen key inserted into its center, turn the tensioner clockwise as far as possible, releasing the spring tension. Then tighten the bolt again to secure the tensioner.







20. On models produced from 05.1998 the tensioner has a different design. The tensioner spring is not used. When installing the belt, the tensioner bracket does not need to be placed on the support plate until the belt is installed on the pulleys (see Fig. 10.20).





21. Install the timing belt. If you are reinstalling the belt after it has been removed, it must be installed with the same side facing up so that it rotates in the same direction. Start installing the belt from the crankshaft pulley, continue counterclockwise, fitting it over the camshaft and tensioner pulleys, and finally fitting the belt over the rear idler pulley. The front section between the crankshaft and exhaust camshaft timing pulleys must be kept under tension without changing the position of the crankshaft and camshafts. If necessary, the position of the camshaft timing pulleys can be changed by turning each pulley on the shaft (which is then held in place by a timing mark aligning device). If the pulley is secured to the shaft, use the tool described in step 18 to prevent the pulley from turning while loosening its mounting bolt. The pulley can then be rotated on the shaft until the belt settles into place. Then tighten the pulley bolt again.

22. On models produced before 05/1998, after installing the belt in place, carefully release the tensioner bolt so that it is again pulled by the spring to the belt. The tensioner should maintain its position, adjacent to the inner toothed belt casing and the cylinder head, and at the same time move, maintaining the belt tension (see Fig. 10.22, a). On models produced since 05/1998, place the tensioner on the support plate and insert the bolt, slightly tightening it (approximately 4 turns). Using a wrench, turn the tensioner so that the arrow aligns with the mark or square hole in the bracket. Then tighten the central bolt (see Fig. 10.22, b).







23. Tighten the bolts of both camshaft toothed pulleys (or check their tightening). Remove the alignment tool. Temporarily install the crankshaft pulley and turn this shaft two turns clockwise to settle and tension the belt, returning the crankshaft (according to the pulley marks) to the position described in step 8. Install the camshaft alignment tool in accordance with step 10. If everything is normal, go to step 26 (see below).

24. If only one camshaft does not align with the alignment tool, fit a scissors-type tool to its toothed pulley and adjust the shaft position. Make sure that the tensioner compensates for the belt slack. Rotate the crankshaft two turns clockwise and fit the camshaft alignment tool to ensure correct installation. If all is well, proceed to step 26.

25. If any of the camshafts is significantly displaced from the required position, then using the device described in paragraph 18., while holding the shaft pulley from turning, loosen the pulley mounting bolt. The camshaft can then be turned (carefully using a wrench) so that the camshaft is aligned with the alignment device. Be careful not to disturb the engagement of the pulley with the toothed belt. Without disturbing the new position of the pulley on the camshaft, tighten the pulley bolt to the required torque (see Fig. 10.25). Remove the camshaft alignment device, turn the crankshaft two turns clockwise and reinstall the device to ensure that it occupies the required position.



26. Once the belt is positioned and tensioned correctly and the camshaft alignment tool fits snugly into the crankshaft pulley marks, tighten the tensioner bolt to the specified torque (see Fig. 10.26). Using a scissors-type tool, hold each pulley by its spokes and ensure that the pulley bolts are tightened to the specified torque. Remove the camshaft alignment tool, rotate the crankshaft two turns clockwise, and reinstall the alignment tool for a final check.



27. On models produced from 05/1998, please note that the tensioner constantly and automatically adjusts the tension due to the force of the internal spring. Therefore, it is not possible to check the tension by pressing on the belt or turning it.

28. The remaining operations are performed in the reverse order of removal, taking into account the following:

• a) Tighten all fasteners to the specified torque.
• b) When installing the right engine/transmission mount, replace the self-locking nuts and do not allow the mount to rock when tightening two (located in the middle) of the six bracket nuts.

(The text was obtained in its entirety from the specified website fordbook)