Adjustment
Before adjusting, turn the engine twice by the crankshaft pulley.
Remove the timing belt cover, see details in paragraphs. 1.3 and 1.7.
Remove the cylinder head cover.
Turn the crankshaft so that the piston in the first cylinder is at TDC, see p. 1.7.
The crankshaft is at TDC in the first cylinder if the groove on the camshaft eccentric is parallel to the upper edge of the cylinder head. The large semicircle should point upwards.
Rotate the engine counterclockwise until the crankshaft pulley is approximately 30° before TDC in the first cylinder (estimate the angle: 1/8 of a circle equals 45°).
For precise adjustment, a TDC adjustment pin is required, such as Ford 21-104. If you don't have one, make your own tool, as shown in the picture.
Unscrew the threaded plug from the cylinder block, which is located on the front wall of the engine under the high-pressure fuel pump.
Screw in special tool Ford 21-104.
Using a spanner, turn the crankshaft clockwise until it stops on the adjusting pin. As a result, the crankshaft is exactly at TDC.
Remove the four timing belt sprocket mounting bolts from the camshaft. The timing belt sprocket should rotate freely on the camshaft.
Install special tool 21-105 or a 5 mm thick steel gasket into the groove on the camshaft eccentric.
Orient the special tool by turning the engine by the crankshaft until the tool is parallel to the top edge of the cylinder head. To check, try sliding templates of the same thickness to the left and right.
Install the adjusting pin -left arrow- into the camshaft sprocket. The diameter of the Ford 23-019 adjusting pin is 6 mm. If you do not have the special tool, use the appropriate pin with a diameter of 6 mm.
Loosen the timing belt tensioner mounting bolt "E", see fig. F-1037.
Attention! A Torx screwdriver, T50, is required for the tensioning device.
Press the belt with your fingers on both sides of the tensioner in the direction indicated by the arrows and release again. This will distribute the belt tension evenly.
Tighten the camshaft sprockets and timing belt tensioner.
Install the high pressure fuel pump gear adjusting pin, see right arrow in Fig. F-10148. The diameter of the adjusting pin for the Bosch high pressure fuel pump is 6 mm, the diameter of the adjusting pin for the Lucas pump is 9.5 mm.
If the pin cannot be installed, then the tension of the toothed belt must be loosened and removed.
Turn the high pressure fuel pump gear until the adjusting pin can be installed.
Place the timing belt in this position and tension it using the spring force of the belt tensioner.
Remove the adjusting pins and steel camshaft spacer.
Screw the threaded plug into the engine block.
Install the cylinder head cover.
Install the upper and lower timing belt covers.
Install the V-belt, see paragraph 1.19.
Connect the ground cable to the battery (-).
If available, set the clock and set the anti-theft code for the radio.
(For more information, please visit the specified website: «FordBook»)