To accurately set the piston of the 1st cylinder to the TDC position of the compression stroke, two special devices are needed to fix the crankshaft and camshafts in a certain position.
You will need: special tools for fixing the crankshaft and camshafts, a "10" socket wrench, ring wrenches or "8", "13" socket heads, an "18" key.
1. Disconnect a wire from the minus plug of the storage battery.
2. Remove the decorative engine cover (see Removal and installation of a decorative casing of the engine).
3. Remove the cylinder head cover (refer to Cylinder Head Cover Gasket Replacement).
4. Remove the right forward wheel.
5. Remove the engine mudguard (see Removal and installation of mudguard and crankcase protection).
6. Remove the right front fender liner (see Removal and installation of wheel mudguards and fender liner).
7. Turn on the neutral gear in the gearbox.
8. Turn the engine crankshaft by the bolt of its pulley so that the hole in the crankshaft pulley approximately 45°does not reach the threaded hole in the timing cover, and the valve cams of the 1st cylinder are directed upwards.
9. Loosen..
10.... and remove the plug located in the front of the cylinder block on the right.
11. Screw in the fixing rod (fixture M10x1.5).
NOTE: This is how the M10x1.5 tool looks like for setting the crankshaft to the TDC position of the compression stroke.
12. Carefully turn the crankshaft by the bolt securing its pulley until the shaft stops with the fixing rod.
13. On Duratec-HE engines with a volume of 2.0 and 2.3 liters, screw the M6x18 bolt through the hole in the crankshaft pulley into the threaded hole in the timing gear cover, thereby fixing the crankshaft from turning.
14. Install the fixing plate in the special grooves at the rear of the camshafts.
15. On a 1.6L Duratec Ti-VCT engine, install the tool so that the marks on its branches are at the top, with the line mark on the exhaust side and the dot on the intake camshaft side.
If the device was installed without difficulty, the piston of the 1st cylinder is at the TDC of the compression stroke and the initial setting of the valve timing is correct.
If the device cannot be installed (shifted valve timing), remove the timing belt, install the locking tool and put on the timing belt correctly (refer to Inspection and replacement of the timing belt for the 1.6L duratec ti-vct engine) or chain (refer to Duratec-he 2.0L and 2.3L Timing Chain Replacement) timing gear drive, depending on the type of engine.
16. Install the removed parts in the reverse order of removal.
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