Timing Belt: Installation
WARNING: This page is about a different car, the 2004 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage can occur.
CAUTION:
The camshaft must be held stationary with an open-ended wrench or a suitable pair of locking pliers. Do not use the alignment tool to hold the camshaft in position or damage to the camshaft may occur.
- Turn the camshafts to the ignition position on cylinder No. 1 and insert the special tool into the camshafts.
- Remove the blanking plug and install the special tool.
- Rotate the crankshaft to TDC on cylinder No. 1.
- Install a new timing belt.
- Starting from the crankshaft timing belt pulley and working counterclockwise install the timing belt, keeping it under tension.
- Pretension the timing belt.
- Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover.
- Position the hexagonal key slot in the tensioner adjusting washer to the 4 o'clock position.
- 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 6 mm hexagonal key.
- Using the hexagonal 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).
- Tighten the bolt, while holding the adjusting washer in position.
- Tighten the camshaft pulley retaining bolts.
- Remove the special tool.
- Remove the special tool 303-465 from the camshafts.
- Check the valve timing by inserting the special tool. Correct it if necessary.
- Install the special tool and make sure that the it is contact with the crankshaft.
- Install the special tool into the camshafts; if necessary loosen the timing pulleys and correct the camshaft alignment.
- Remove the special tools.
- Install the intake camshaft pulley blanking plug.
- Install the blanking plug.
- Install the spark plugs.
- Install the valve cover.
- Tighten the bolts in two stages.
- Stage 1: 2 Nm.
- Stage 2: 7 Nm.
- Attach the PCV hose to the valve cover.
- Connect the VCT actuator electrical connector.
- Coat the spark plug thread with anti-seize grease, screw in the spark plugs and push in the spark plug connector until it engages.
- Tighten the bolts in two stages.
- Connect the VCT valve electrical connector.
- Install the engine cover.
- Install the ignition coil pack cover.
- Attach the retaining clips.
- Attach the coolant pipe to the retaining clip.
- Install the engine front mount bracket.
- Attach the timing belt upper cover.
- Install the accessory drive belt idler.
- Install the engine front mount.
- Attach the power steering pump fluid reservoir.
- Attach the coolant expansion tank.
- Remove the hydraulic jack and wooden block.
- Raise and support the vehicle. For additional information, refer to JACKING AND LIFTING .
- Attach the lower timing belt cover.
- Install the coolant pump pulley retaining bolts.
- Install the crankshaft pulley.
- Install the accessory drive belt.
- Rotate the accessory drive belt tensioner clockwise.
- Install the accessory drive belt.
- Tighten the bolts on the coolant pump pulley.
- Attach the drive belt cover.
- Lower the vehicle.
- Connect the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
- Standard finishing operations:
- Connect the battery negative cable.
- Install the battery cover.
- Check fluid levels and correct if necessary.
- Check the routing of vacuum hoses and cables and secure them with cable ties.
NOTE:
Do not tighten the bolts. The camshaft timing pulleys must be able to turn freely on the camshafts.
NOTE:
At TDC the crankshaft keyway is in the 12 o'clock position.
NOTE:
Rotate the crankshaft clockwise.
NOTE:
Make sure that the crankshaft contacts the timing peg.
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.
CAUTION:
Incorrect timing belt tension will result in incorrect valve timing.
CAUTION:
Tension the timing belt, working counterclockwise.
NOTE:
Use an open-ended wrench to prevent the camshaft from rotating.
NOTE:
Turn the crankshaft two revolutions in the normal direction of rotation.
NOTE:
Use an open-ended wrench to prevent the camshaft from rotating.
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.
NOTE:
Position the upper timing belt cover and the center timing belt.
NOTE:
Check the seating of the timing belt upper cover gasket and correct as necessary.
NOTE:
Do not tighten the bolts at this stage.
NOTE:
Direction of travel on a used drive belt.
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.