Timing Belt: Installation

NOTE: Do not tighten the bolts. The camshaft timing pulleys must be able to turn freely on the camshafts.

Fig 1: Inserting Special Tool Into Camshafts

Courtesy of FORD MOTOR CO.

Turn the camshafts to ignition position on cylinder number 1 and insert the special tool into the camshafts.

NOTE: Rotate the crankshaft clockwise.

Fig 2: Rotating Crankshaft For Positioning Cylinder Number 1 To TDC Position

Courtesy of FORD MOTOR CO.

Rotate the crankshaft to TDC on cylinder number 1.

NOTE: Cylinders No. 1 and No. 4 are at TDC when the Woodruff key points straight up.

Fig 3: Removing Blanking Plug

Courtesy of FORD MOTOR CO.

Remove the blanking plug, completely screw in the special tool and auto-align the crankshaft to TDC.

CAUTION: Do not kink the timing belt (do not bend the timing belt less than a diameter of 35 mm).

CAUTION: Do not rotate the crankshaft, check that it is still resting against the timing pin.

NOTE: The lug of the belt tensioner must not be hooked into the sheet metal cover during timing belt installation.

Position a new timing belt in place.
- Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension.
  
  Fig 4: Installing Timing Belt
  Courtesy of FORD MOTOR CO.

CAUTION: Incorrect timing belt tension will cause incorrect valve timing.

Pre tension the timing belt.
1. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover.
2. Position the hex key slot in the tensioner adjusting washer to the 4 o'clock position.
3. Tighten the attaching bolt enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 6mm hex key.
  
  Fig 5: Tightening Attaching Bolt For Seating Tensioner Against Rear Timing Cover
  Courtesy of FORD MOTOR CO.

CAUTION: Tension the timing belt, working counterclockwise.

Fig 6: Rotating Adjusting Washer Counterclockwise Until Notch In Pointer Centered Over Index Line On Locating Tab

Courtesy of FORD MOTOR CO.

Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment).
While holding the adjusting washer in position, tighten the bolt.

Fig 7: Tightening Bolt
Courtesy of FORD MOTOR CO.

CAUTION: Do not tighten the camshaft timing pulley bolts against Special Tool 303-465; use Special Tool 303-098 to prevent movement.

NOTE: The crankshaft must remain at TDC on cylinder number 1.

Fig 8: Tightening Camshaft Timing Pulleys Bolts

Courtesy of FORD MOTOR CO.

Tighten the bolts of the camshaft timing pulleys.
Unscrew and remove Special Tool 303-574.
Remove Special Tool 303-465 from the camshafts.

NOTE: Turn the crankshaft two revolutions in the normal direction of rotation.

Check the valve timing by inserting the special tool. Correct it if necessary.
- Screw in Special Tool 303-574 and make sure that the crankshaft is touching it.
- Insert Special Tool 303-465 into the camshafts; if necessary loosen the timing pulleys and correct the camshaft alignment.
- Detach the special tools.
Screw in and tighten the blanking plug.

Fig 9: Tightening Blanking Plug
Courtesy of FORD MOTOR CO.

CAUTION: Use a blunt object (a plastic cable tie) to apply the silicone grease, to avoid damaging the spark plug connectors.

CAUTION: Push on the spark plug connectors, keeping them in line with the spark plugs.

NOTE: Coat the inside of the spark plug connectors with silicone grease to a depth of 5-10 mm.

Install the cylinder head cover and spark plugs.
1. 1. Tighten the bolts in two stages.
  - Stage 1: 2 N.m
  - Stage 2: 7 N.m
2. 4. Attach the PCV hose.
3. 5. Coat the spark plug thread with Never Seeze, screw in the spark plugs and push in the spark plug connector until it engages.
  
  Fig 10: Installing Spark Plug And Spark Plug Connector
  Courtesy of FORD MOTOR CO.

NOTE: Put the upper timing belt cover together with the center timing belt cover in place.

Fig 11: Installing Timing Belt Center Cover/Front Engine Mounting Bracket

Courtesy of FORD MOTOR CO.

Attach the timing belt center cover/front engine mounting bracket.

NOTE: Check the seating of the timing belt upper cover gasket and correct it if necessary.

Fig 12: Installing Timing Belt Upper Cover

Courtesy of FORD MOTOR CO.

Attach the timing belt upper cover.
Install the front engine mounting.

Fig 13: Installing Front Engine Mounting
Courtesy of FORD MOTOR CO.
Connect the PAS reservoir.

Fig 14: Connecting PAS Reservoir
Courtesy of FORD MOTOR CO.
Install the coolant expansion tank.

Fig 15: Installing Coolant Expansion Tank
Courtesy of FORD MOTOR CO.
Pull the jack out towards the front of the vehicle.
Raise and support the vehicle.
Attach the lower timing belt cover.

Fig 16: Installing Lower Timing Belt Cover
Courtesy of FORD MOTOR CO.
Attach the crankshaft pulley/vibration damper.

Fig 17: Installing Crankshaft Pulley/Vibration Damper
Courtesy of FORD MOTOR CO.

NOTE: Direction of travel on a used drive belt.

Install the drive belt.
1. 1. Attach the multi-groove belt idler pulley.
  - Attach the coolant pump pulley.
2. 3. Install the drive belt by turning clockwise and tension it.
3. 4. Tighten the bolts on the coolant pump pulley.
  
  Fig 18: Installing Drive Belt
  Courtesy of FORD MOTOR CO.
Attach the drive belt cover.

Fig 19: Installing Drive Belt Cover
Courtesy of FORD MOTOR CO.
Lower the vehicle.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

Standard finishing operations:
- Connect the battery negative cable.
- Check fluid levels and correct if necessary.
- Check the routing of vacuum hoses and cables and secure them with cable ties.