Ford Workshop Service and Repair Manuals

Universal Flange Holding Wrench

205-072

Timing Peg, Crankshaft TDC

303-193

Support Bar, Engine

303-290A

Adapter for 303-290A

303-290-03A

Adapter for 303-290A

303-290-13

Adapters for 303-290A

303-290A-15, 303-290A-15/5, 303-290A-15/6, 303-290A-15/6, 303-290A-15/7

Alignment Plate, Camshaft

303-376

Locking Tool, Flywheel

303-393

Remover, Camshaft Sprocket

303-651

1. Disconnect the battery ground cable.
   For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

2. Remove the valve cover.
   For additional information, refer to: Valve Cover (303-01F Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, In-vehicle Repair).
   

3. Remove the crankcase vent oil separator.
   For additional information, refer to: Crankcase Vent Oil Separator (303-08E Engine Emission Control - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).
   

4. Detach the coolant expansion tank from the wheel housing and position it to one side.

5. Remove the charge air cooler outlet pipe.
   1. Remove the fuel line retaining clip.
   2. Remove the charge air cooler outlet pipe retaining nut.
   3. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
   4. Loosen the charge air cooler outlet pipe retaining clamps.

6. Remove the fuel line retaining clip.

7. Remove the fuel filter crash protection top shield.

8. Clean the fuel filter, fuel supply lines and surrounding areas.
   For additional information, refer to: Fuel Injection Component Cleaning (303-04G, General Procedures).
   

9. Disconnect the fuel filter fuel supply line quick release coupling.
   For additional information, refer to: Quick Release Coupling (310-00, General Procedures).
   
   • Install a clean blanking cap to the fuel filter fuel supply line.

10. Disconnect the fuel filter fuel to fuel pump supply line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00, General Procedures).
    
    • Install a clean blanking cap to the fuel filter fuel supply line.

11. Detach the fuel filter retaining bracket from the cylinder head.
    1. Disconnect the cylinder head temperature (CHT) sensor electrical connector and detach it from the engine lifting eye.
    2. Remove the engine lifting eye.
    3. Loosen the fuel filter retaining bracket retaining bolt.

12. 

    NOTE:Only rotate the camshaft in the normal direction of rotation.
    Using the camshaft groove as a guide, rotate the crankshaft to 5 degrees before top dead center (TDC).

13. Remove the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 1.8L Duratorq-TDCi (Kent) Diesel (303-05, Removal and Installation).
    

14. Remove the generator drive coupling.
    1. Remove the driveshaft intermediate bearing retaining bolts.
    2. Loosen the vibration damper retaining bolts.

15. Detach the starter motor from the transaxle and position it to one side.

16. Install the special tool.
    • Remove the cylinder block blanking plug and install the special tool.

17. 

    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Rotate the crankshaft to TDC.
    • Rotate the crankshaft slowly until the crankshaft stops.

18. 

    CAUTION:Make sure that the crankshaft does not rotate during installation of the special tool.
    

    CAUTION:Make sure that the crankshaft is at the TDC position before locking the special tool.
    

    CAUTION:Make sure that the special tool engages correctly.
    Using the special tool, lock the crankshaft.

19. Install the special tools.

20. Install the special tools.

21. Install the special tools.

22. Lower the vehicle.

23. Remove the engine front mount.

24. Remove the engine front mount stud.

25. Remove the timing belt cover.

26. Install the special tool.

27. Remove the timing belt tensioner.

28. Using the special tool, loosen the camshaft pulley retaining bolt by 5 turns.

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

30. Remove and discard the timing belt.

1. 

   NOTE:Install only latest level timing belts. These are identified by a laser etched Ford logo.
   Check the new timing belt.

2. Check the timing belt tensioner.
   1. Make sure that the timing belt tensioner pointer rotates clockwise freely.
   2. Arrow denotes counterclockwise rotation of the timing belt tensioner.

3. 

   NOTE:Move the timing belt tensioner adjustment arm to the 3 o'clock position.
   

   NOTE:Do not fully tighten the timing belt tensioner retaining bolt at this stage.
   Install the timing belt tensioner.

4. 

   CAUTION:Never install a used timing belt.
   

   CAUTION:Install the timing belt with the direction arrows in the direction of engine rotation.
   

   CAUTION:Only install the timing belt after the engine has cooled to workshop temperature.
   

   NOTE:Install a new timing belt.
   Install the timing belt.

5. 

   NOTE:The camshaft pulley must be able to rotate freely on the camshaft taper.
   Tighten the camshaft pulley bolt finger tight and then loosen by one-half turn.

6. 

   NOTE:Using an Allen key, maintain tension until the timing belt tensioner retaining bolt is tightened.
   Tension the timing belt.
   1. Rotate the timing belt tensioner adjustment arm counterclockwise to tension the timing belt slightly.
   2. The pointer must be positioned between the sides of the window.
   3. Tighten the timing belt tensioner retaining bolt.

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

8. Remove the special tool.

9. Raise and support the vehicle. For additional information, refer to: (100-02 )

   Jacking (Description and Operation),

   Lifting (Description and Operation).

10. Release the special tool.

11. Remove the special tool.

12. 

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

    NOTE:Using paint or typing correction fluid, mark the crankshaft pulley to show top dead center (TDC).
    Rotate the crankshaft 6 revolutions.

13. Install the special tool.

14. 

    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Rotate the crankshaft to TDC.
    • Rotate the crankshaft slowly until the crankshaft stops.

15. 

    CAUTION:Make sure that the crankshaft is at the TDC position before locking the special tool.
    

    CAUTION:Make sure that the special tool engages correctly.
    Using the special tool, lock the crankshaft.

16. Lower the vehicle.

17. 

    CAUTION:If the pointer is not visible in the timing belt tensioner window, the timing belt tensioning steps must be repeated.
    Check that the timing belt tensioner pointer is positioned in the window.

18. 

    CAUTION:If the special tool cannot be installed, the timing belt tensioning steps must be repeated.
    Install the special tool.

19. Remove the special tool.

20. Remove the special tool.

21. Install the timing belt cover.

22. Install the engine front mount stud.

23. Install the engine front mount.

24. Raise and support the vehicle. For additional information, refer to: (100-02 )

    Jacking (Description and Operation),

    Lifting (Description and Operation).

25. Remove the special tools.

26. Remove the special tools.

27. Remove the special tools.

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

29. Attach the starter motor to the transaxle.

30. Install the generator drive coupling.

31. Install the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 1.8L Duratorq-TDCi (Kent) Diesel (303-05, Removal and Installation).
    

32. Attach the fuel filter retaining bracket to the cylinder head.
    1. Tighten the fuel filter retaining bracket retaining bolt.
    2. Install the engine lifting eye.
    3. Connect the cylinder head temperature (CHT) sensor electrical connector and attach it to the engine lifting eye.

33. Connect the fuel filter fuel to fuel pump supply line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00, General Procedures).
    
    • Remove and discard the blanking cap.

34. Connect the fuel filter fuel supply line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00, General Procedures).
    
    • Remove and discard the blanking cap.

35. Install the fuel filter crash protection top shield.

36. Install the fuel line retaining clip.

37. Install the charge air cooler outlet pipe.
    1. Tighten the charge air cooler outlet pipe retaining clamps.
    2. Connect the the manifold absolute pressure (MAP) sensor electrical connector.
    3. Install the charge air cooler outlet pipe retaining nut.
    4. Install the fuel line retaining clip.

38. Attach the coolant expansion tank to the wheel housing.

39. Install the crankcase vent oil separator.
    For additional information, refer to: Crankcase Vent Oil Separator (303-08E Engine Emission Control - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).
    

40. Install the valve cover.
    For additional information, refer to: Valve Cover (303-01F Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, In-vehicle Repair).
    

41. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
    

42. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11, General Procedures).