Ford Workshop Service and Repair Manuals

Universal flange holding wrench

15-030 A

Timing peg, crankshaft TDC position

21-104

Engine support bar

21-140

Adapter for 21-140

21-140-01

Adapter for 21-140

21-140-02

Adapter for 21-140

21-140-03

Centering tool, remover and installer, oil seal

21-148 A

Remover, crankshaft timing pulley

21-200

Angle gauge, bolt tightening

21-540

Timing pin, injection pump timing

23-019

Timing pin, injection pump timing

23-029

1. Standard preparatory operations.
   • Make a note of the radio keycode.
   • Make a note of the preset radio stations.

2. Disconnect the battery ground cable.

3. Attach the engine support bar.

4. Remove the front engine mounting auxiliary bracket.

5. Remove the front engine mounting bracket.

6. Remove the upper timing belt cover.

7. Raise the engine with the engine support bar.

8. Remove the top bolts of the lower timing belt cover.

9. Remove the injection pump timing belt cover.

10. Remove the injection pump timing belt.
    • Slacken the bolts of the timing pulley.
    • Loosen the clamp bolt of the timing belt tensioner and slacken the timing belt.
    • Tighten the clamp bolt of the timing belt tensioner.
    • Remove the timing belt.

11. Lower the engine with the engine support bar.

12. Raise the vehicle.
    1. Undo the bolt.
    
    CAUTION:To slacken, turn the bolt clockwise.
    2. Slacken and remove the drive belt.

13. Remove the drive belt.

14. Remove the crankshaft pulley/vibration damper.

15. Remove the lower timing belt cover.

16. Remove the drive belt tensioner.

17. Disconnect the alternator and remove it.

18. Turn the crankshaft to the TDC position.
    • Unscrew the blanking plug from the cylinder block.
    
    NOTE:The timing pin must be screwed in as far as it will go.
    • Screw in the timing pin.
    • Carefully turn the crankshaft in the normal direction of rotation of the engine until it comes up against the timing pin.

19. Lower the vehicle.

20. Slacken the bolts of the camshaft timing pulley.

21. Remove the camshaft timing belt.
    1. Slacken the clamp bolt of the timing belt tensioner.
    2. Slacken the timing belt by compressing the spring using water pump pliers.

22. Tighten the clamp bolt of the timing belt tensioner. Remove the timing belt.

23. Raise the vehicle.

24. Remove the flange of the crankshaft front timing pulley.

25. Remove the crankshaft rear timing pulley.

26. Mount the special tool.
    • Screw in the flange bolt of the crankshaft front timing pulley.
    
    NOTE:Position of the flattened area on the special tool.
    • Locate the special tool.
    • Pre-punch four holes with a punch and screw in the self-tapping screws.

27. Pull out the oil seal, together with the flange bolt, from the crankshaft front timing pulley.

1. 

   CAUTION:Only install the timing belt when the engine has cooled down. The engine must have been switched off for at least four hours.
   

   NOTE:Position of the flattened area on the special tool.
   Check the alignment of the front plate. If necessary, center the front plate.
   1. Front plate
   2. Crankshaft
   3. Special Tool

2. 

   CAUTION:Carry out Step 3 immediately after Step 2 to prevent the oil seal from contracting. Only remove the support ring immediately prior to installation of the oil seal.
   

   NOTE:Position of the flattened area on the special tool.
   

   NOTE:The support ring must not yet be removed from the oil seal.
   

   NOTE:Fit the oil seal dry.
   Fit the oil seal, together with the bolt of the crankshaft front timing pulley flange.
   • Remove the special tool and the support ring.

3. Fit the crankshaft rear timing pulley.
   Coat the O-ring and the end of the crankshaft with engine oil.
   
   NOTE:The guide pin in the end of the crankshaft and the hole in the timing pulley must line up.
   • Carefully slide the timing pulley on as far as the stop.

4. 

   NOTE:Use a new bolt.
   

   NOTE:Coat the contact face of the bolt head with engine oil.
   Fit the flange of the crankshaft front timing pulley.

5. Lower the vehicle.

6. Align the injection pump timing pulley and turn the crankshaft to the TDC position.
   1. Slacken the bolts of the timing pulley.
   2. Align the injection pump timing pulley by inserting the timing pin through the cutout in the timing pulley and the hole in the injection pump housing. Unscrew the blanking plug from the cylinder block.
   
   NOTE:The timing pin must be screwed in as far as it will go; the crankshaft must be resting against the timing pin.
   3. Screw the timing pin into the cylinder block. Carefully turn the crankshaft in the normal direction of rotation of the engine until it comes up against the timing pin.

7. 

   CAUTION:Renew the timing belt.
   

   CAUTION:Only install the timing belt when the engine has cooled down. The engine must have been switched off for at least four hours.
   

   NOTE:Make sure the belt is seated correctly.
   

   NOTE:The running direction of the timing belt is marked.
   

   NOTE:The bolts must not be at the ends of their slots.
   Fit the injection pump timing belt.
   1. Fit the timing belt with the slack side nearest the timing belt tensioner. Slacken the bolt of the timing belt tensioner and let the timing belt tensioner snap against the timing belt.
   2. Tighten the timing belt tensioner bolt.
   3. Tighten the bolts of the timing pulley.

8. 

   CAUTION:Renew the timing belt.
   

   NOTE:The direction of rotation is marked.
   

   NOTE:Make sure the belt is seated correctly.
   

   NOTE:The bolts must not be at the ends of their slots.
   Fit the timing belt with the slack side nearest the timing belt tensioner. Slacken the clamp bolt of the timing belt tensioner and let the timing belt tensioner snap against the belt.
   1. Tighten the clamp bolt of the timing belt tensioner.
   2. Tighten the bolts of the timing pulley.

9. Remove timing pins 21-104, 23-019 and 23-029.

10. Preparations for tensioning the timing belts.
    
    NOTE:Turn the crankshaft two turns in the normal direction of rotation of the engine until the slot in the injection pump timing pulley is at 12 o'clock.
    
    NOTE:Turn the slot back counter to the normal direction of rotation to 11 o'clock.
    1. Screw in the timing pin.
    
    NOTE:Carefully turn the crankshaft in the normal direction of rotation of the engine until it comes up against the timing pin.
    2. The timing pin must be able to be inserted in the camshaft timing pulley.
    3. Timing pin 23-029 must be able to be inserted in the injection pump timing pulley.

11. 

    CAUTION:Used timing belts must not be retensioned.
    

    NOTE:Slacken the bolts of the timing pulleys just half a turn each.
    

    NOTE:The crankshaft must remain in the TDC position.
    Tension the injection pump timing belt. Slacken the bolts of the camshaft timing pulley. Slacken the bolts of the injection pump timing pulley.
    1. Slacken the bolt of the injection pump timing belt tensioner a quarter turn so that the timing belt tensioner presses against the timing belt.
    2. Tighten the bolt of the injection pump timing belt tensioner.
    3. Tighten the bolts of the injection pump timing pulley.

12. 

    CAUTION:Used timing belts must not be retensioned.
    Tension the camshaft timing belt.
    
    NOTE:Leave timing pin 23-029 inserted.
    1. Slacken the bolt of the camshaft timing belt tensioner a quarter turn so that the timing belt tensioner presses against the timing belt.
    
    NOTE:All the timing pins must be properly inserted; the crankshaft must be resting against the timing pin.
    2. Tighten the bolt of the camshaft timing belt tensioner.
    3. Tighten the bolts of the camshaft timing pulley. Take out the timing pins.
    4. Fit the blanking plug.

13. Fit the injection pump timing belt cover.

14. Raise the vehicle.

15. Screw in the lower bolts of the lower timing belt cover.

16. Fit the crankshaft pulley/vibration damper.

17. 

    CAUTION:Position the generator and screw in the bolts finger tight. First tighten the bolt on the pulley side, then the rear upper long bolt and finally the rear lower short bolt.
    Install the alternator and connect it.

18. Fit the drive belt tensioner.

19. Fit the drive belt.
    1. Fit the drive belt and tension it as described in Operation No. 31 413 0.
    2. Tighten the bolt.

20. Lower the vehicle.

21. Raise the engine with the engine support bar.

22. Screw in the remaining bolts of the lower timing belt cover.

23. Lower the engine with the engine support bar.

24. Fit the upper timing belt cover.

25. Fit the front engine mounting bracket.

26. Attach the front engine mounting auxiliary bracket.

27. Detach the engine support bar.

28. Connect the battery ground cable.

29. Standard finishing operations.
    • Enter the radio keycode.
    • Reprogram the preset radio stations.
    • Reset the clock.
    • Carry out a road test to enable the PCM (EEC V) to collect data.