ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Exhaust Manifold > < Camshaft

Galaxy 2000.75 (04.2000-02.2006)

Engine - 2.3L - Timing Chain Galaxy 2000.75 (04/2000-02/2006)
In-vehicle Repair

Special Tool(s)

Flange holding wrench, universal

205-072 (15-030 A)

Angle gauge, bolt tightening

303-174 (21-540)

Support bar, engine

303-290A (21-140A)

Adapter for 303-290A

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

Adapter for 303-290A

303-290-04A (21-140-04A)

Adapter for 303-290A

303-290-07 (21-140-07)

Adapters for 303-338 (studs)

303-338-01 (21-153-01)

Remover, vibration damper hub

303-509 (21-213)

Installer, crankshaft vibration damper

303-510 (21-214)
General Equipment
2.5 mm drill bit
Brass drift
Materials
Name
Specification
Engine oil
WSS-M2C913–A or WSS-M2C912–A1 
Silicon grease
A960-M1C171-AA 
High-temperature grease
ESDM-M1C220-A 

Removal

  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Remove the air cleaner. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.

  1. Remove the air cleaner outlet pipe body.

  1. Remove the bulkhead cover.

  1. Remove the spark plug cover.

  1. Disconnect the spark plug wires from the spark plugs.

  1. Detach the generator wiring harness support guide from the cylinder head.
  1. Remove the hood. For additional information, refer to Section  501-02 Front End Body Panels.

  1. Install the special tools.

  1. Remove the engine front mounting bracket and disconnect the ground cable from the mounting bracket.
    1. Disconnect the ground cable from the engine front mounting bracket.
    1. Remove the engine front mounting bracket nuts and bolts.

  1. Remove the engine support plate bracket.

  1. Remove the engine front mounting.

  1. Remove the engine lower support plate retaining bolts together with the engine support plate.

  1. Disconnect the camshaft position (CMP) sensor electrical connector.

  1. Remove the valve cover.
    • Discard the gasket.

  1. Remove the upper front cover.
    • Discard the gasket.

  1. Rotate the crankshaft in its normal direction until piston No. 1 is on top dead center.

  1. Remove the timing chain upper guide.
    • Discard the timing chain upper guide.

  1. Using the special tool, remove the camshaft sprockets.

  1. CAUTION:
    CAUTION:Prevent the retaining washer from dropping into the timing case.
    NOTE:
    NOTE:Using a suitable piece of wire prevent the timing chain from dropping into the timing case.
    Remove the timing chain tensioner.
    1. Remove the retaining washer.
    1. Using a M6 x 60 bolt, remove the timing chain tensioner pivot bolt.

  1. Remove the timing chain tensioner.
    • Discard the timing chain tensioner.

  1. Remove the lower front cover retaining bolts.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the engine undershield (two nuts and four bolts).
  1. Drain the engine oil.
    • Discard the oil drain plug washer.

  1. NOTE:
    NOTE:Install a new oil drain plug washer.
    Install the oil drain plug.
  1. Remove the accessory drive belt. For additional information, refer to Section  305-05 .

  1. Using three M8 x 25 bolts, attach the special tool to the crankshaft pulley.
    • Apply grease on the mating face of the special tool and the crankshaft pulley retaining bolt.

  1. Using the special tool, remove the crankshaft pulley.
    • Using two M8 x 30 bolts, install the special tool.

  1. Detach the power steering line from the engine.

  1. Remove the lower front cover (12 bolts).
    • Discard the front cover.

  1. CAUTION:
    CAUTION:Wrap the flutes of the drill bit with a suitable tape. Failure to follow this instruction may result in personal injury.
    Remove the oil pump chain tensioner.
    • Tension the oil pump chain tensioner, lock it in position with a 2.5 mm drill bit and remove it.

  1. Remove the oil pump chain guides.
  1. Remove the oil pump chain.

  1. Remove the timing chain guide lower retaining bolt.
  1. Lower the vehicle.

  1. Remove the timing chain guide upper retaining bolt.
  1. Remove the timing chain and the timing chain guide.

Installation
  1. CAUTION:
    CAUTION:Fully or partially released timing chain tensioners must not be used (whether new or used).
    Check the new timing chain tensioner.

  1. CAUTION:
    CAUTION:Install a new timing chain tensioner.
    Install the timing chain tensioner.
  1. NOTE:
    NOTE:The single copper colored link must be at the lower end of the chain guide.
    Install the timing chain and the timing chain guide.
    • Using a suitable piece of wire, prevent the timing chain from dropping into the timing case.

  1. Install the timing chain guide upper retaining bolt.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. NOTE:
    NOTE:The copper link of the timing chain must align with the timing marks on the crankshaft timing sprocket.
    Install the timing chain.

  1. Tighten the timing chain guide lower retaining bolt.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:Prevent the retaining washer from dropping into the timing case.
    Install the timing chain tensioner.
    1. Using a M6 x 60 bolt, install the timing chain tensioner pivot bolt.
    1. Install the retaining washer.

  1. CAUTION:
    CAUTION:The camshaft sprockets must locate in the slots on the camshaft.
    NOTE:
    NOTE:The copper links of the timing chain must align with the timing marks on the camshaft sprocket.
    NOTE:
    NOTE:The timing chain must be taut on the long side.
    Install the exhaust camshaft sprocket and the timing chain.
    • If necessary rotate the camshaft slightly.

  1. NOTE:
    NOTE:The copper links of the timing chain must align with the timing marks on the camshaft sprockets.
    NOTE:
    NOTE:The timing chain may hang down slightly between the camshaft sprockets.
    Install the inlet camshaft sprocket and the timing chain.
  1. Tighten both camshaft sprocket retaining bolts finger tight.

  1. Using a suitable brass drift, release the timing chain tensioner.

  1. Using the special tool, tighten the camshaft sprocket retaining bolts.

  1. Rotate the crankshaft in its normal direction until piston No. 2 is on TDC.
    • Make sure the marks on the camshaft sprockets face one another exactly on level with the upper edge of the cylinder head.

  1. CAUTION:
    CAUTION:If the timing chain had to be removed while adjusting the valve timing, a new timing chain tensioner must be installed.
    Check the valve timing.
    • Rotate the crankshaft one revolution in its normal direction and set it to the marks.

  1. NOTE:
    NOTE:Install a new timing chain upper guide.
    Install the timing chain upper guide.
  1. NOTE:
    NOTE:Make sure piston No. 2 is on TDC.
    NOTE:
    NOTE:The copper link of the timing chain must align with the timing marks on the crankshaft timing sprocket and on the balancer shaft sprocket.
    Install the oil pump chain.

  1. Install the oil pump chain guides.

  1. WARNING:
    WARNING:Wrap the flutes of the drill bit with a suitable tape. Failure to follow this instruction may result in personal injury.
    Install the oil pump chain tensioner.
    • Install the oil pump chain tensioner retaining bolt.
    • Remove the drill bit.

  1. NOTE:
    NOTE:A new lower front cover is supplied with an alignment sleeve that must be removed following installation.
    Install the lower front cover (12 bolts).
  1. Remove the alignment sleeve.

  1. Attach the power steering line to the engine.

  1. Using the special tool, install the crankshaft pulley.

  1. Using three M8 x 25 bolts, attach the special tool to the crankshaft pulley.

  1. Using the special tools and two M8 x 30 bolts,, tighten the crankshaft pulley retaining bolt.
    • Tighten the bolt in two stages.
    • Stage 1: 52 Nm.
    • Stage 2: 85 degrees.
  1. Install the accessory drive belt. For additional information, refer to Section  305-05 .
  1. Lower the vehicle.

  1. Install the lower front cover retaining bolts (four bolts).

  1. NOTE:
    NOTE:Install a new gasket.
    NOTE:
    NOTE:Align the upper edge of the upper cover with the cylinder head mating face (maximum downward offset = 0.13 mm)
    Install the upper front cover.

  1. NOTE:
    NOTE:Install a new gasket.
    Install the valve cover (4 nuts and 11 bolts).
    • Tighten the nuts bolts in the sequence shown in two stages.
    • Stage 1: Tighten nuts and bolts 1 through 15 to 3 Nm.
    • Stage 2: Tighten nuts and bolts 1 through 15 to 9 Nm.

  1. Connect the CMP sensor electrical connector.

  1. Install the engine support plate.

  1. Install the engine front mounting.

  1. Install the engine support plate bracket.

  1. Install the engine front mounting bracket and connect the ground cable to the mounting bracket.
    1. Install the bolts.
    1. Install the nut.
    1. Connect the ground cable.

  1. Remove the special tools.
  1. Install the hood. For additional information, refer to Section  501-02 Front End Body Panels.

  1. Attach the generator wiring harness support guide to the cylinder head.
  1. Using a suitable blunt object to avoid damage to the spark plug connector gasket, coat the inside of the spark plug connector with silicone grease to a depth of 5-10 mm.

  1. CAUTION:
    CAUTION:Connect the spark plug wires in line with the spark plugs.
    Connect the spark plug wires to the spark plugs.

  1. Install the spark plug cover.

  1. Install the bulkhead cover.
  1. Install the air cleaner outlet pipe.
  1. Install the air cleaner. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Install the engine undershield (two nuts and four bolts).
  1. Lower the vehicle.

Exhaust Manifold > < Camshaft