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Ford Workshop Service and Repair Manuals

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In-vehicle Repair|Oil Pan > < Camshaft Seal

Fusion 2002.75 (06.2002-)

Engine - 1.6L Duratorq-TDCi (DV) Diesel - Timing Belt Fusion 2002.75 (06/2002-)
In-vehicle Repair

Special Tool(s)

Remover/Installer, Hose Clamp

303-397

Alignment Peg, Crankshaft

303-732

Locking Tool, Crankshaft

303-734

Alignment Peg, Camshaft

303-735
General Equipment
Trolley jack
CAUTION:
CAUTION:Only install the timing belt after the engine has cooled to workshop temperature.
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Remove the air cleaner.
    For additional information, refer to: Air Cleaner - 1.6L Duratorq-TDCi (DV) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Remove the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 1.6L Diesel.
  1. Drain the coolant expansion tank.

  1. CAUTION:
    CAUTION:Protect the generator with lint free material to prevent contamination.
    Using the special tool, disconnect the coolant expansion tank hose.
    • Detach the coolant expansion tank and position to one side.

  1. CAUTION:
    CAUTION:Do not support the engine directly on the oil pan.
    Using a trolley jack and suitable wooden blocks, support the engine.

  1. Remove the engine front mount.
    • Discard the bolts.

8. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Timing belt upper cover retaining bolts
2
-
Timing belt upper cover
3
-
Engine front mount bracket retaining bolts
4
-
Engine front mount bracket
5
-
Crankshaft pulley retaining bolt
See Removal Detail
6
-
Crankshaft pulley
See Installation Detail
7
-
Timing belt lower cover retaining bolts
8
-
Timing belt lower cover

 
Item
Part Number
Description
9
-
Timing belt
See Installation Detail
10
-
Timing belt tensioner
11
-
Camshaft pulley
See Removal Detail
See Installation Detail
12
-
Crankshaft timing pulley
See Removal Detail
See Installation Detail

9. To install, reverse the removal procedure.

Removal Details

Item 5 : Crankshaft pulley retaining bolt
  1. NOTE:
    NOTE:Do not discard the old crankshaft pulley retaining bolt at this stage.
    Using a suitable power tool, remove the crankshaft pulley retaining bolt.

Item 11 : Camshaft pulley
  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Align the camshaft.
    • Turn the crankshaft until the alignment hole in the camshaft pulley is at the 10 o'clock position.

Item 12 : Crankshaft timing pulley
  1. Remove the timing belt guide.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Remove the crankshaft timing pulley.

Installation Details

Item 12 : Crankshaft timing pulley
  1. Check the correct position of the crankshaft timing pulley Woodruff key.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    NOTE:
    NOTE:Install the old crankshaft pulley bolt.
    NOTE:
    NOTE:Do not fully tighten the old crankshaft pulley bolt at this stage.
    Install the crankshaft timing pulley.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Using the special tool, align the crankshaft.

Item 11 : Camshaft pulley
  1. Using the special tool, align the camshaft pulley.

Item 9 : Timing belt
  1. Using the special tool, align the high-pressure fuel pump pulley (engine shown removed for clarity).

  1. Remove the special tool (engine shown removed for clarity).

  1. Remove the special tool.

  1. NOTE:
    NOTE:Make sure that the camshaft pulley alignment holes are in line.
    Check the camshaft alignment.
  1. CAUTION:
    CAUTION:Install the timing belt with the direction arrows in the direction of crankshaft rotation.
    NOTE:
    NOTE:Install a new timing belt.
    Install the timing belt.

  1. NOTE:
    NOTE:Using an Allen key, maintain tension on the timing belt until the timing belt tensioner bolt is tightened.
    Tension the timing belt (engine shown removed for clarity).
    1. Turn the timing belt tensioner adjustment arm counterclockwise 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. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Remove the special tool.

  1. Install the timing belt guide.

  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Rotate the crankshaft ten revolutions.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Using the special tool, align the crankshaft.

  1. Install the special tool.
    • If the special tool cannot be installed, repeat the previous steps.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Remove the special tool.

  1. Remove the special tool.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Remove the crankshaft pulley retaining bolt.
    • Discard the bolt.

Item 6 : Crankshaft pulley
  1. CAUTION:
    CAUTION:Make sure that the special tool engages correctly.
    NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Using the special tool, lock the flywheel.
    • Rotate the crankshaft until the special tool aligns with one of the slots in the flywheel.

  1. NOTE:
    NOTE:Install a new crankshaft pulley retaining bolt.
    Install the crankshaft pulley.
    • Tighten the crankshaft pulley bolt in two stages.
    • Stage 1: 30 Nm.
    • Stage 2: 180 degrees.

  1. Remove the special tool.

In-vehicle Repair|Oil Pan > < Camshaft Seal