Removing and installing a toothed belt (diesel) (Mondeo 1)

The diesel engine is equipped with two toothed belts. Before removing the high-pressure fuel pump belt "B", you should remove the camshaft drive belt "A". After installing one or both belts, you need to check and, if necessary, adjust the valve timing mechanism. This requires three adjustment mandrels, which you can make yourself. The toothed belt can only be removed from a cold engine.

Removal

Disconnect the negative (-) cable from the battery.

Warning! This will erase data in electronic memory devices, such as the engine fault memory device or the radio code. Please read the section carefully "Removing and installing the battery", before disconnecting it.

Disconnect the multi-pin connector of the power steering pressure sensor. The sensor is located on top near the timing belt cover.

Unscrew the return and pressure hoses from the power steering oil pump.

Caution! Collect hydraulic oil. Close the holes with suitable plugs.

Unscrew the power steering pump belt pulley from the high pressure fuel pump sprocket.

Remove all V-belts (air conditioning, generator, power steering), see paragraph 1.19.





Raise the vehicle onto jack stands. Unscrew the wheel arch trim "1". Unscrew the V-belt pulley protective cover "2".



Disconnect the upper protective cover of the toothed belt "arrow". Unscrew the bolt above the high-pressure fuel pump and remove the cover.

Raise the car. Disconnect the lower protective cover of the toothed belt from the bottom of the car by unscrewing two bolts.

Turn the crankshaft so that it is at TDC in the first or fourth cylinder. To do this, shift the gearbox to neutral. Apply the parking brake. Place a SW32 offset open-end wrench on the central bolt of the crankshaft belt pulley and rotate the belt pulley clockwise. Other methods for turning the engine: engage 5th gear and move the car on a level surface.





The crankshaft is exactly at TDC in the first or fourth cylinder, if the adjusting pins can be installed. The adjusting pins for the camshaft sprocket and the Bosch high-pressure fuel pump gear have a diameter of 6 mm. If a Lucas high-pressure fuel pump is used, then an adjusting pin with a diameter of 9 mm is used for the high-pressure fuel pump gear.

Loosen the mounting bolts of the timing belt tensioners "D" and "E", see Fig. P-1037. The "D" belt tensioner requires a T50 Torx screwdriver.

Remove the timing belts. Once the timing belt is removed, the engine should not be turned over again. Otherwise, the pistons and valves will be damaged.

Installation

Place both timing belts in place, being careful not to turn the timing belt sprockets.

Caution! The arrows on the toothed belts must match the direction of engine rotation (to the right). If the toothed belts are worn or oily, they must be replaced.

Start laying the belts from the sprockets on the crankshaft and continue laying them counterclockwise, i.e. in the following sequence: crankshaft sprocket, camshaft or high-pressure fuel pump sprocket, tension sprocket. As a result, the looser branch of the toothed belt will come to the tension rollers, which are under the influence of the spring.



Allow the spring to press the tension rollers against the timing belts, tighten the tension roller bolts "D" and "E" to a torque of 50 Nm.

Finally, check the valve timing mechanism and adjust it if necessary, see the next section.

Remove the adjusting pins.

Install the lower and upper timing belt covers.

Screw the V-belt pulley to the high-pressure fuel pump sprocket with three bolts. Install the V-belt, see paragraph 1.19.

Screw the pressure and return hoses to the brake booster oil pump.

Connect the multi-pin plug to the pressure sensor.

Connect the ground wire to the battery. Set the clock, set the anti-theft code for the radio.

Fill the power steering reservoir with hydraulic oil and bleed it, see item 28.4.