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Timing Belt: Removal

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.
  1. General Instructions.
    • The positions of the engine mounting and the engine roll restrictor are described looking from the transmission toward the engine.
    • If necessary, use special tool 412-108 to remove coolant and ventilation hoses.
    • Due to special model variants, some steps do not apply to all vehicles. These are clearly marked in the text.
    • If necessary, cut the cable ties and install new cable ties on installation.
  2. Disconnect the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Raise and support the vehicle. For additional information, refer to JACKING AND LIFTING .
  4. Detach the drive belt cover.
    Fig 1: Detaching Drive Belt Cover
    G04034967Courtesy of FORD MOTOR CO.
  5. Loosen the coolant pump pulley retaining bolts.
    Fig 2: Loosening Coolant Pump Pulley Retaining Bolts
    G04034968Courtesy of FORD MOTOR CO.
  6. Remove the accessory drive belt.
    1. Rotate the accessory drive belt tensioner clockwise.
    2. Remove the accessory drive belt.
    Fig 3: Removing Accessory Drive Belt
    G04034969Courtesy of FORD MOTOR CO.
  7. Remove the crankshaft pulley.
    Fig 4: Removing Crankshaft Pulley
    G04034970Courtesy of FORD MOTOR CO.
  8. Remove the coolant pump pulley.
    Fig 5: Removing Coolant Pump Pulley
    G04034971Courtesy of FORD MOTOR CO.
    9. CAUTION: The removal of the lower part of the engine front cover is necessary to avoid damage to the timing belt.
    Fig 6: Detaching Timing Belt Lower Cover
    G04034972Courtesy of FORD MOTOR CO.
  9. Detach the timing belt lower cover.
  10. Lower the vehicle.
  11. Detach the coolant expansion tank and position it to one side.
    Fig 7: Detaching Coolant Expansion Tank
    G04034973Courtesy of FORD MOTOR CO.
  12. Detach the power steering fluid reservoir and position it to one side.
    Fig 8: Detaching Power Steering Fluid Reservoir
    G04034974Courtesy of FORD MOTOR CO.
    13. CAUTION: Insert a suitable wooden block between the oil pan and the trolley jack.
  13. Position the hydraulic jack with the wooden block under the oil pan and raise the engine so that the engine front mount is free from load.
    14. NOTE: Mark the position of the engine front mount.
    Fig 9: Removing Engine Front Mount
    G04034975Courtesy of FORD MOTOR CO.
  14. Remove the engine front mount.
  15. Remove the accessory drive belt idler pulley.
    Fig 10: Removing Accessory Drive Belt Idler Pulley
    G04034976Courtesy of FORD MOTOR CO.
  16. Detach the timing belt upper cover.
    • Leave the timing belt cover in its installed position.
    Fig 11: Detaching Timing Belt Upper Cover
    G04034977Courtesy of FORD MOTOR CO.
  17. Remove the engine front mount bracket.
    • Remove the timing belt upper cover.
    Fig 12: Removing Engine Front Mount Bracket
    G04034978Courtesy of FORD MOTOR CO.
  18. Remove the ignition coil pack cover.
    1. Detach the retaining clips.
    2. Detach the coolant pipe from the retaining clip.
    Fig 13: Removing Ignition Coil Pack Cover
    G04034979Courtesy of FORD MOTOR CO.
  19. Remove the engine upper cover.
    Fig 14: Removing Engine Upper Cover
    G04034980Courtesy of FORD MOTOR CO.
  20. Disconnect the variable cam timing (VCT) valve electrical connector.
    Fig 15: Disconnecting Variable Cam Timing Valve Electrical Connector
    G04034981Courtesy of FORD MOTOR CO.
    21. CAUTION: Do not pull the cable when removing the spark plug connectors. If necessary, remove the ignition cables from the ignition coil to avoid kinking the cables. Turn the spark plug connectors slightly before removing to loosen the seal.
    CAUTION: Pull off the spark plug connectors in line with the spark plugs.
    NOTE: Loosening sequence: from the outside to the inside, working diagonally.
    Fig 16: Removing Valve Cover
    G04034982Courtesy of FORD MOTOR CO.
  21. Remove the valve cover.
    1. Disconnect the spark plug connectors.
    2. Detach the positive crankcase ventilation (PCV) hose.
    3. Fully loosen 10 bolts.
  22. Remove the spark plugs.
    Fig 17: Removing Spark Plugs
    G04034983Courtesy of FORD MOTOR CO.
    23. NOTE: At TDC the crankshaft keyway is in the 12 o'clock position.
  23. Turn the engine to 60$$ BTDC on cylinder number 1.
    24. NOTE: Use an open-ended wrench to prevent the camshaft from rotating.
    Fig 18: Removing Intake Camshaft Pulley Blanking Plug
    G04034984Courtesy of FORD MOTOR CO.
  24. Remove the intake camshaft pulley blanking plug.
    25. NOTE: Use an open-ended wrench to prevent the camshaft from rotating.
    Fig 19: Loosening Camshaft Pulley Retaining Bolts
    G04034985Courtesy of FORD MOTOR CO.
  25. Loosen the camshaft pulley retaining bolts.
  26. Detension the timing belt (timing belt shown removed for clarity).
    1. Loosen the bolt four turns.
    2. Position the tensioner so that the locating tab is at approximately the 4 o'clock position.
    3. Line up the hexagonal key slot in the tensioner adjusting washer with the pointer that is located behind the pulley.
    Fig 20: Positioning Tensioner
    G04034986Courtesy of FORD MOTOR CO.
  27. Remove the timing belt.
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