Duratec

Timing Belt




NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.

Special Tools:

Removal

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 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 ties and install new cable ties on installation.


2. Disconnect the battery negative cable.

3. Raise and support the vehicle.






4. Detach the drive belt cover






5. Loosen the coolant pump pulley retaining bolts.






6. Remove the accessory drive belt.
1. Rotate the accessory drive belt tensioner clockwise.
2. Remove the accessory drive belt.






7. Remove the crankshaft pulley.






8. Remove the coolant pump pulley.






9. CAUTION: The removal of the lower part of the engine front cover is necessary to avoid damage to the timing belt.
Detach the lower timing belt cover.

10. Lower the vehicle.






11. Detach the coolant expansion tank and position it to one side.






12. Detach the PAS reservoir and position it to one side.

13. CAUTION: Insert a suitable wooden block between the oil pan and the hydraulic jack.
Position the hydraulic jack with the wooden block under the oil pan and raise so that the engine front mount is free from load.






14. NOTE: Mark the position of the engine front mount.
Remove the engine front mount.






15. Remove the accessory drive belt idler pulley.






16. Detach the timing belt upper cover.
- Leave the timing belt cover in its installed position.






17. Remove the engine front mount bracket.
- Remove the timing belt upper cover.






18. Remove the ignition coil pack cover.
1. Detach the retaining clips.
2. Detach the coolant pipe from the retaining clip.






19. Remove the engine cover.






20. Disconnect the VCT valve electrical connector.






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.

Remove the valve cover.
1. Disconnect the spark plug connectors.
2. Detach the positive crankcase ventilation (PCV) hose.
3. Fully loosen ten bolts.






22. Remove the spark plugs.


23. NOTE:At TDC the crankshaft keyway is in the 12 o'clock position.
Turn the engine to 60 degrees BTDC on cylinder number 1.






24. NOTE: Use an open ended wrench or suitable pliers to prevent the camshaft rotating from rotating.
Remove the intake camshaft pulley blanking plug.






25. NOTE: Use an open ended wrench or suitable pliers to prevent the camshaft rotating from rotating.
Loosen the camshaft pulley retaining bolts.






26. Detension the timing belt (timing belt removed for clarity).
1. Loosen the bolt four turns.
2. Position the tensioner so 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.


27. Remove the timing belt.



Installation

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

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






2. NOTE: Rotate the crankshaft clockwise.

Rotate the crankshaft to TDC on cylinder number 1






3. Remove the blanking plug and using the special tool, align the crankshaft to TDC on cylinder number 1.






4. 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.

Install a new timing belt.
- Starting from the crankshaft timing belt pulley and working counterclockwise install the timing belt, keeping it under tension.






5. CAUTION: Incorrect timing belt tension will result in incorrect valve timing.

Pretension 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 hexagonal 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 6 mm hexagonal key.






6. CAUTION: Tension the timing belt, working counterclockwise.

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).






7. Tighten the bolt, while holding the adjusting washer in position.






8. NOTE: Use an open ended wrench or suitable locking pliers to prevent the camshaft rotating from rotating.

Tighten the camshaft pulley retaining bolts.






9. Remove the special tool.






10. Remove Special Tool.

11. NOTE: Only rotate the crankshaft in the normal direction of rotation.

Rotate the engine two revolutions.






12. Using the special tool, align the crankshaft to TDC.






13. NOTE: If it is not possible to install the special tool, correct the valve timing.

Using the special tool, check the position of the camshafts, if necessary loosen the timing pulleys and correct the camshaft alignment.






14. NOTE: Use an open ended wrench or suitable locking pliers to prevent the camshaft rotating from rotating.

Install the intake camshaft pulley blanking plug.

15. Remove the special tools.






16. Install the blanking plug.






17. Install the spark plugs.






18. 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 valve cover.
1. Tighten the bolts in two stages.
- Stage 1: 2 Nm
- Stage 2: 7 Nm
2. Attach the PCV hose to the valve cover.
3. Coat the spark plug thread with Never Seeze, screw in the spark plugs and push in the spark plug connector until it engages.






19. Connect the VCT valve electrical connector.






20. Install the engine cover.






21. Install the ignition coil pack cover.
1. Attach the retaining clips.
2. Attach the coolant pipe to the retaining clip.






22. NOTE: Position the upper timing belt cover and the center timing belt.

Install the engine front mount bracket.






23. NOTE: Check the seating of the timing belt upper cover gasket and correct as necessary.

Attach the timing belt upper cover.






24. Install the accessory drive belt idler.






25. Install the engine front mount.






26. Attach the PAS reservoir.






27. Attach the coolant expansion tank.


28. Remove the hydraulic jack and wooden block.


29. Raise and support the vehicle.






30. Attach the lower timing belt cover.






31. NOTE: Do not tighten the bolts at this stage.

Install the coolant pump pulley retaining bolts.






32. Install the crankshaft pulley.






33. NOTE: Direction of travel on a used accessory drive belt.

Install the accessory drive belt.
1. Rotate the accessory drive belt tensioner clockwise.
2. Install the accessory drive belt.






34. Tighten the bolts on the coolant pump pulley.






35. Attach the drive belt cover.


36. Lower the vehicle.



37. Connect the battery.


38. 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.
- 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.