Fig. 5.16. Engine components removed when replacing the timing belt: 1 – crankshaft pulley; 2 – lower cover of the timing drive; 3 – timing belt drive; 4 - front timing gear cover; 5 – bracket of the right support of the power unit suspension; 6 – water pump pulley.
Checking the timing belt is performed as follows.
1. Remove the front timing cover.
2. Inspect the condition of the timing belt. Replace the belt if, upon inspection, you find: – traces of oil on any surface of the belt; - traces of wear on the toothed surface, cracks, cuts, folds and separation of the fabric from the rubber; - cracks, folds, depressions or bulges on the outer surface of the belt; – fraying or delamination on the end surfaces of the belt.
WARNING: A belt with traces of engine oil on any of its surfaces must be replaced, as oil quickly destroys rubber. The reason for oil getting on the belt (usually due to a leak in the crankshaft and camshaft seals) must be eliminated immediately.
3. Check the belt tension. A correctly tensioned belt should turn 90° with a finger force of 15–20 N (1.5–2 kgf) applied in the middle between the crankshaft and camshaft pulleys.
4. Install the parts in the reverse order of removal.
Replacing the timing belt is performed as follows.
NOTE: Carry out work on an inspection pit, overpass or, if possible, on a lift.
You will need: special devices for locking the camshafts and crankshaft, as well as the timing belt tension roller, a 10 mm socket wrench, 8 mm and 13 mm open-end wrenches or socket heads, and an 18 mm wrench.
1. Remove the air conditioning compressor drive belt and the accessory drive belt (see Checking and replacing the accessory drive belt).
2. Remove the generator (see Removing and installing the generator).
3. Place a secure support under the engine.
4. Remove the right powertrain mount (see Replacing the right powertrain suspension support).
5. Remove pulley 6 (Fig. 5.16) of the water pump by unscrewing the four bolts that secure it.
6. Remove bracket 5 (Fig. 5.17) of the right support of the power unit suspension by unscrewing the three bolts that secure it.
7. Remove the front cover 4 (see Fig. 5.16) of the timing drive by unscrewing the eight bolts that secure it.
Fig. 5.17. Fastening the bracket of the right support of the power unit suspension.
8. Set the gearshift lever to neutral position.
9. Turn the engine crankshaft by the bolt securing its pulley so that the marks on the VCT (variable valve timing) mechanisms of the camshafts are positioned as shown in Fig. 5.18 ("at 11 o"clock").
Fig. 5.18. Setting marks on VCT mechanisms.
10. Unscrew the plug located in the front part of the cylinder block on the right (Fig. 5.19) and install the locking rod into the opened hole until it stops against the crankshaft (see Setting the piston of the first cylinder to the TDC position of the compression stroke).
Carefully turn the crankshaft by the bolt securing its pulley until the shaft stops with the locking rod.
Fig. 5.19. Plug for the hole for installing the crankshaft locking rod.
NOTE: The locking rod is a cylindrical part about 65 mm long, stepped in diameter. The small diameter part of the rod (4 mm), 10 mm long, is a shank that enters the groove of the crankshaft. The remaining cylindrical part of a larger diameter (8 mm) serves as a guide in the cylinder block hole.
11. Secure the camshafts from turning by installing a locking device in the special grooves in the VCT mechanism housings (Fig. 5.20).
Install the device so that the marks on the device branches are at the top, and the mark in the form of a line should be on the side of the exhaust camshaft, and the mark in the form of a dot should be on the side of the intake camshaft.
Fig. 5.20. Fixing the camshafts from turning with a special device.
12. Engage 4th gear in a manual transmission (or set the automatic transmission selector to the "P" position – parking) and brake the car with the parking brake to prevent the engine crankshaft from turning.
13. Unscrew the pulley mounting bolt (Fig. 5.21) to the crankshaft nose and remove the pulley.
CAUTION: Do not reuse the crankshaft pulley bolt.
Fig. 5.21. Crankshaft pulley and its fastening
14. Unscrew the three bolts securing the lower timing cover and remove the cover.
Fig. 5.22. Loosening the timing belt tension.
15. Loosen the timing belt tension by moving the leading branch of the belt as far as possible in the direction shown by the arrow in Fig. 5.22. The tension roller will then move to its original position. Fix the tension roller in this position by inserting a metal rod of suitable diameter into the holes in the roller and its bracket.
16. Remove the belt from the VCT timing pulleys, crankshaft and tensioner roller.
CAUTION: Do not turn the crankshaft with the timing belt removed, as the pistons will damage the valves.
17. Place the new belt on the exhaust camshaft VCT timing pulley. Tighten the leading strand of the belt and place it on the intake camshaft VCT timing pulley. Then tighten the leading strand of the belt and place it on the crankshaft timing pulley. Place the driven strand of the belt behind the tension roller.
18. Check the correct installation of the belt on the toothed pulleys and remove the locking rod from the holes of the tension roller and its bracket. In this case, the tension roller spring will set the required belt tension.
19. Install the lower timing cover and crankshaft pulley. Tighten the crankshaft pulley mounting bolt in two stages: 1st – with a torque of 40 N·m (4 kgf·m); 2nd – turn it 90°.
20. Remove the locking device from the housings of the variable valve timing system mechanisms of the camshafts.
21. Remove the crankshaft locking rod from the hole in the cylinder block (see item 11).
22. Engage neutral gear in the gearbox, turn the crankshaft two revolutions and stop it in a position in which the marks on the VCT mechanism housings take the position shown in Fig. 5.18.
23. Install the locking rod into the hole in the cylinder block (see item 11) and carefully turn the crankshaft until it is secured with the rod.
24. Install the locking device on the VCT mechanism housings (see Fig. 5.20). If the device can be installed without difficulty, the timing belt is installed correctly. If the device cannot be installed (the valve timing is shifted), remove the belt, install the locking device and repeat the belt installation as described above.
25. If the timing belt is installed correctly, remove the locking device from the VCT housings, remove the locking rod from the hole in the cylinder block, replace the plug of this hole, tightening it to a torque of 20 N·m (2 kgf·m), and install all removed parts in the reverse order of removal.
(Information for this article was taken from the website: FORDBOOK)