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Exhaust Manifold > < Camshaft Seal

Focus 1999 (08.1998-12.2004)

Engine - 1.8L Diesel - Timing Belt Focus 1999 (08/1998-12/2004)
In-vehicle Repair

Special Tool(s)

Universal Flange Holding Wrench

205-072 (15-030A)

Timing Peg, Crankshaft TDC

303-193 (21-104)

Support Bar, Engine

303-290A (21-140A)

Adapter for 303-290A

303-290-01 (21-140-01)

Adapter for 303-290A

303-290-02 (21-140-02)

Adapter for 303-290A

303-290-03A (21-140-03A)

Alignment Plate, Camshaft

303-376 (21-162B)

Locking Tool, Flywheel

303-393 (21-168)

Remover, Camshaft Sprocket

303-651 (21-229)
Materials
Name
Specification
Coolant
ESDM-97B49-A 
Engine oil
WSS-M2C912-A1 

Removal

All vehicles
  1. CAUTION:
    CAUTION:Never install a used timing belt.
    CAUTION:
    CAUTION:Only install the timing belt after the engine has cooled to workshop temperature.
    Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Remove the valve cover.
    For additional information, refer to: Valve Cover (303-01B, In-vehicle Repair).

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

  1. Remove the charge air cooler cover.

  1. Disconnect the intake air temperature (IAT) sensor electrical connector.

  1. Remove the charge air cooler.

  1. Detach the power steering pipe retaining bracket from the cylinder head.

  1. Using the camshaft groove as a guide, turn the crankshaft to five degrees before top dead center (TDC).
  1. Remove the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 1.8L Duratorq-TDDi (Lynx) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel (303-05, Removal and Installation).
Vehicles built up to 05/2007
  1. Remove the generator drive coupling.
    1. Driveshaft intermediate bearing retaining bolts.
    1. Vibration damper retaining bolts.
Vehicles built 05/2007 onwards
  1. Remove the generator.
    For additional information, refer to: Generator - Vehicles Built From: 05/2007 1.8L Duratorq-TDCi (Lynx) Diesel (414-02, Removal and Installation).

All vehicles
  1. Install the special tool.
    • Remove the cylinder block blanking plug and install the special tool.

  1. Detach the starter motor and position it to one side.
  1. NOTE:
    NOTE:Only turn the crankshaft in the normal direction of rotation.
    Turn the crankshaft to TDC.
    • Turn the crankshaft slowly until the crankshaft stops.

  1. CAUTION:
    CAUTION:Make sure that the crankshaft does not rotate during installation of the special tool.
    CAUTION:
    CAUTION:Make sure crankshaft is at the TDC position before locking the special tool.
    CAUTION:
    CAUTION:Make sure that the special tool engages correctly.
    Using the special tool, lock the crankshaft.
  1. Lower the vehicle.

  1. Install the special tools.
Vehicles built up to 04/2001
  1. Remove the engine front mount.
Vehicles built 04/2001 onwards
  1. Remove the engine front mount.
All vehicles
  1. Remove the engine front mount stud.

  1. Remove the timing belt cover.

  1. Install the special tool.

  1. Remove the timing belt tensioner.
Engines with mechanical timing belt tensioner
  1. Discard the timing belt tensioner.
All vehicles
  1. Remove and discard the timing belt.

  1. Using the special tool, loosen the camshaft pulley retaining bolt by five turns.

  1. Using the special tool, loosen the camshaft pulley.

Installation

All vehicles
  1. NOTE:
    NOTE:Install only latest level timing belts. These are identified by a laser etched Ford logo.
    Check the new timing belt.
Engines with mechanical timing belt tensioner
  1. Install a new automatic timing belt tensioner.
All vehicles
  1. Check the automatic timing belt tensioner.
    1. Make sure that the tensioner pointer rotates clockwise freely.
    1. Arrow denotes counter clockwise rotation of tensioner.

  1. NOTE:
    NOTE:Move timing belt tensioner adjustment arm to 3 o'clock position.
    Install the timing belt tensioner and tighten the bolt finger tight.
  1. CAUTION:
    CAUTION:Never install a used timing belt.
    CAUTION:
    CAUTION:Install the timing belt with the direction arrows in the direction of engine rotation.
    CAUTION:
    CAUTION:Only install the timing belt after the engine has cooled to workshop temperature.
    NOTE:
    NOTE:Install a new timing belt.
    Install the timing belt.

  1. NOTE:
    NOTE:The camshaft pulley must be able to turn freely on the camshaft taper.
    Tighten the camshaft pulley bolt finger tight and then loosen by 1/2 a turn.

  1. NOTE:
    NOTE:Using an allen key, maintain tension until the tensioner bolt is tightened.
    Tension the timing belt.
    1. Turn the timing belt tensioner adjustment arm counter clockwise to tension the timing belt slightly.
    1. The pointer must be positioned between the sides of the window.
    1. Tighten the timing belt tensioner retaining bolt.

  1. Using the special tool, tighten the camshaft pulley retaining bolt.

  1. Remove the special tool.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02, Description and Operation).

  1. Release the special tool.

  1. Remove the special tool.

  1. NOTE:
    NOTE:Only turn the crankshaft in the normal direction of rotation.
    NOTE:
    NOTE:Using paint or typing correction fluid, mark the crankshaft pulley to show top dead center (TDC).
    Turn the crankshaft six revolutions.

  1. Install the special tool.
  1. NOTE:
    NOTE:Only turn the crankshaft in the normal direction of rotation.
    Turn the crankshaft to TDC.
    • Turn the crankshaft slowly until the crankshaft stops.

  1. CAUTION:
    CAUTION:Make sure that the crankshaft does not rotate during installation of the special tool.
    CAUTION:
    CAUTION:Make sure crankshaft is at the TDC position before locking the special tool.
    CAUTION:
    CAUTION:Make sure that the special tool engages correctly.
    Using the special tool, lock the crankshaft.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:The auto tensioner pointer may move slightly upwards in the window.
    Check that the autotensioner pointer is positioned in between the sides of the window.
    1. If the pointer is in the window, go to the following step.
    1. If the pointer is not in the window, repeat procedure from the previous steps.

  1. Install the special tool.
    • If the special tool cannot be installed, repeat the procedure from the previous steps.
  1. Remove the special tools.

  1. CAUTION:
    CAUTION:Do not damage the timing belt cover.
    NOTE:
    NOTE:Only rework the timing belt cover, if there was a mechanical timing belt tensioner installed.
    Using a suitable file, modify the timing belt cover.

  1. Install the timing belt cover.

  1. Install the engine front mount stud.
Vehicles built up to 04/2001
  1. Install the engine front mount.
Vehicles built 04/2001 onwards
  1. Install the engine front mount.
All vehicles
  1. Remove the special tools.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02, Description and Operation).

  1. Remove the special tool and install the blanking plug.

  1. Attach the starter motor.
Vehicles built up to 05/2007
  1. Install the generator drive coupling.
Vehicles built 05/2007 onwards
  1. Install the generator.
    For additional information, refer to: Generator - Vehicles Built From: 05/2007 1.8L Duratorq-TDCi (Lynx) Diesel (414-02, Removal and Installation).
All vehicles
  1. Install the accessory drive belt. For additional information, refer to: Accessory Drive Belt - 1.8L Duratorq-TDDi (Lynx) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel (303-05, Removal and Installation).

  1. Attach the power steering pipe retaining bracket to the cylinder head.

  1. Install the charge air cooler.

  1. Connect the intake air temperature (IAT) sensor electrical connector.

  1. Install the charge air cooler cover.

  1. Install the coolant expansion tank.
  1. Install the valve cover.
    For additional information, refer to: Valve Cover (303-01B, In-vehicle Repair).
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
Vehicles with front and rear power windows
  1. Initialize the door window motors.

Exhaust Manifold > < Camshaft Seal