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Home >> Ford >> 2003 >> ZX2 Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 1310 (Engine - 2.0L ZETEC) >> In-Vehicle Repair >> Timing Belt >> Removal

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.
  1. General Instructions.
    • The positions of the engine mounting and the engine roll restrictor are described looking from the transmission towards the engine.
    • If necessary, use Special Tool 412-108 to remove coolant and ventilation hoses.
    • Owing to special model variants, some steps do not apply to all vehicles. These are clearly marked in the text.
    • If necessary, cut the cable tie and install new on installation.
    2. CAUTION: Disconnect the battery negative cable.
  2. Raise and support the vehicle. For additional information, refer to JACKING AND LIFTING .
  3. Detach the drive belt cover.
    Fig 1: Detaching Drive Belt Cover
    G04033942Courtesy of FORD MOTOR CO.
    4. NOTE: Mark the drive belt running direction.
    Fig 2: Removing Drive Belt
    G04033943Courtesy of FORD MOTOR CO.
  4. Remove the drive belt.
    1. Loosen the bolts on the coolant pump pulley.
    2. Slacken the drive belt by turning clockwise and remove it.
      • Detach the coolant pump belt pulley.
    3. Detach the multi-groove belt idler pulley.
  5. Detach the crankshaft pulley/vibration damper.
    Fig 3: Detaching Crankshaft Pulley/Vibration Damper
    G04033944Courtesy of FORD MOTOR CO.
    6. CAUTION: The removal of the lower part of the engine front cover is necessary to avoid damage to the timing belt.
    Fig 4: Detaching Lower Timing Belt Cover
    G04033945Courtesy of FORD MOTOR CO.
  6. Detach the lower timing belt cover.
  7. Lower the vehicle.
  8. Detach the coolant expansion tank and lay it to one side.
    Fig 5: Detaching coolant expansion tank and lay it to one side
    G04033946Courtesy of FORD MOTOR CO.
  9. Remove the PAS reservoir and lay it to one side.
    Fig 6: Removing PAS Reservoir
    G04033947Courtesy of FORD MOTOR CO.
    10. CAUTION: Insert the wooden block between the oil pan and the jack.
  10. Position the jack with the wooden block under the oil pan and raise so that the front engine mounting is free from load.
    11. NOTE: Mark the position of the engine mounting.
    Fig 7: Removing Front Engine Mount
    G04033948Courtesy of FORD MOTOR CO.
  11. Remove the front engine mounting.
  12. Detach the timing belt upper cover.
    • Leave the timing belt cover in its installed position.
    Fig 8: Detaching Timing Belt Upper Cover
    G04033949Courtesy of FORD MOTOR CO.
  13. Detach the timing belt center cover/front engine mounting bracket.
    • Remove the timing belt upper cover.
    Fig 9: Removing Timing Belt Upper Cover
    G04033950Courtesy of FORD MOTOR CO.
    14. 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 10: Removing Cylinder Head Cover
    G04033951Courtesy of FORD MOTOR CO.
  14. Remove the cylinder head cover.
    1. Pull off the spark plug connectors.
    2. Detach the PCV hose.
    3. Remove ten bolts.
  15. Remove the spark plugs.
  16. Turn the engine to TDC on cylinder No. 1.
  17. Detension the timing belt.
    1. Unscrew the bolt four turns.
    2. Position the tensioner so the locating tab is at approximately the 4 o'clock position.
    3. Line up the hex key slot in the tensioner adjusting washer with the pointer that is located behind the pulley.
    Fig 11: Removing Timing Belt Tension
    G04033952Courtesy of FORD MOTOR CO.
  18. Remove and discard the timing belt.
  19. Slacken the camshaft timing pulleys.
    • Prevent from turning using the special tool.
    Fig 12: Loosening Camshaft Timing Pulley Bolts
    G04033953Courtesy of FORD MOTOR CO.
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