ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Exhaust Manifold > < Camshaft Seal

Puma 1998 (06.1997-12.2001)

Engine - 1.4L Zetec-SE (Sigma)/1.6L - Timing Belt Puma 1998 (06/1997-12/2001)
In-vehicle Repair

Special Tool(s)

Universal flange holding wrench

205-072 (15-030A)

Alignment tool, camshaft

303-376 (21-162B)

Pliers, spark plug connector

303-622 (21-226)

Angle gauge, bolt tightening

303-174 (21-540)

Installer, crankshaft vibration damper

303-510 (21-214)

Remover, crankshaft vibration damper

303-511 (21-215)

Socket, spark plug

303-499 (21-202)

Alignment pin, crankshaft TDC setting

303-507 (21-210)
General Equipment
Workshop jack
Materials
Name
Specification
Lubricant (spark plug threads - Never Seeze)
ESE-M1244-A 
Silicone grease
ESE-M1C171-AA 

Removal

All Vehicles
  1. Disconnect the battery negative lead. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Loosen the bolts on the coolant pump pulley.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the drive belt cover.

  1. Slacken and remove the drivebelt (vehicle from MY '99 shown).
Vehicles built up to 07/1998
  1. Remove the crankshaft pulley/vibration damper.
    • Apply grease as lubricant to the special tool.
    1. Attach the special tool using two M8 x 40 bolts.
    1. Extract the crankshaft pulley/vibration damper by screwing the bolt out.
Vehicles built from 08/1998
  1. Remove the crankshaft pulley/vibration damper.
    1. Attach the special tool using two bolts (M10 x 40 and M10 x 45) and two nuts.
    1. Remove the bolt.
    • Counterhold using the special tool.
All vehicles
  1. Remove the coolant pump pulley and the drive belt idler pulley.

  1. Remove the bolts of the timing belt covers.
    1. Remove the bolts of the timing belt upper cover.
    1. Remove the bolts of the timing belt lower cover.
    • Take out the lower cover.
  1. Lower the vehicle.

  1. Remove the cover plate from the cylinder head cover.
    1. Open the wiring harness cover and disconnect the crankcase breather hose.
    1. Remove the screws.
    • Unscrew the oil filler cap.

  1. CAUTION:
    CAUTION:Do not pull the cable when removing the spark plug connector. If necessary disconnect the plug from the ignition coil to avoid bending the cable. Turn the spark plug connector slightly before removing to loosen the seal.
    CAUTION:
    CAUTION:When pulling off the spark plug connector keep it in line with the spark plug.
    CAUTION:
    CAUTION:Do not damage the cylinder head cover gasket as it cannot be renewed separately.
    Remove the cylinder head cover, lifting it straight up.
    1. Pull off the spark plug connectors.
    • Use Special Tool 303-622 for angled spark plug connectors.
    1. Remove the three bolts of the timing belt upper cover.
    1. Unscrew the nuts.

  1. Detach the coolant expansion tank.
    • Unscrew the bolt and lay the expansion tank to one side.
Vehicles built up to 07/1998
  1. Remove the generator.
    1. Pull out the plugs.
    1. Disconnect the lead.
    1. Unscrew the three screws.
Vehicles built from 08/1998
  1. Remove the generator and lay it to one side.
    1. Disconnect the plugs.
    1. Disconnect the positive cable.
    1. Remove the bolts and detach the studs.
  1. Position a workshop jack with a wooden support underneath the oil pan and jack it up slightly to take the load off the front engine mounting.
Vehicles built up to 07/1998
  1. Remove the front engine mounting bracket.
Vehicles built from 08/1998
  1. Remove the engine mounting.
  1. Remove the timing belt upper cover.
Vehicles built up to 07/1998
  1. Remove the front engine mounting bracket.
Vehicles built from 08/1998
  1. Remove the front engine mounting bracket (shown on an engine removed from the vehicle).
Timing belt tensioner with cam
  1. NOTE:
    NOTE:Mark the running direction of the timing belt if it is to be re-used.
    Slacken and remove the timing belt (shown on an engine removed from a vehicle).
    • Undo the bolt.
Timing belt tensioner with slot
  1. NOTE:
    NOTE:Mark the running direction of the timing belt if it is to be re-used.
    Slacken and remove the timing belt (shown on an engine removed from a vehicle).
    • Undo the bolts.

Installation

All Vehicles
  1. CAUTION:
    CAUTION:Prevent from turning using the special tool.
    CAUTION:
    CAUTION:The timing pulley bolts can be re-used once.
    Loosen the bolts until the camshaft timing pulleys are free to turn on the camshafts.
    • If necessary mark the timing pulley bolts with paint. Renew any bolts that already have paint markings.

  1. Remove the spark plugs with the special tool.

  1. Set the camshaft to TDC on cylinder no. 1 and insert the special tool.
    • Turn the camshafts by the hexagon with a 21mm open ended spanner until the special tool can be inserted.
  1. NOTE:
    NOTE:Marking of running direction.
    Lay the timing belt in place.
    • Lay the timing belt in place, starting with the crankshaft timing pulley and working anti-clockwise.

  1. Attach the timing belt lower cover (shown from below).
Vehicles built up to 07/1998
  1. NOTE:
    NOTE:Use the bolt removed from the crankshaft pulley/vibration damper.
    Install the crankshaft pulley/vibration damper.

  1. NOTE:
    NOTE:Use a new bolt.
    Screw in the bolt of the crankshaft pulley/vibration damper.
    • Tighten the bolt in two stages.
    • Stage 1: 40 Nm
    • Stage 2: 90 degrees
Vehicles built from 08/1998
  1. NOTE:
    NOTE:Use a new bolt.
    Install the crankshaft pulley/vibration damper.
    • Tighten the bolt in two stages.
    • Stage 1: 40 Nm
    • Stage 2: 90 degrees
All vehicles
  1. NOTE:
    NOTE:If it is not possible to insert the special tool, rotate the crankshaft anti-clockwise back through approx. 20 degrees.
    Set the crankshaft to TDC on cylinder no. 1.
    • Remove the blanking plug and screw in the special tool.
    • Carefully rotate the crankshaft clockwise until the crankshaft web rests against the special Tool 21-210.
Timing belt tensioner with cam
  1. NOTE:
    NOTE:Do not turn the cam when tightening. Counterhold using an Allen key.
    Tension the timing belt (shown on an engine removed from a vehicle).
    • Turn the cam anti-clockwise using a 6 mm Allen key until the pointer is positioned in the exact centre of the square recess.
    • Tighten the bolt.
Timing belt tensioner with slot
  1. Tension the timing belt (shown on an engine removed from a vehicle).
    • Tension with an 8 mm Allen key until the pointer is positioned in the exact centre of the square recess.
    • Tighten the bolts.
All vehicles
  1. CAUTION:
    CAUTION:Do not tighten the camshaft timing pulleys against Special Tool 303-376.
    NOTE:
    NOTE:The timing pulley bolts can be re-used once.
    NOTE:
    NOTE:The crankshaft and the camshaft must not turn.
    Tighten the bolts of the camshaft timing pulleys.
  1. Remove Special Tool 303-376.

  1. Remove the special tool (shown from below).
  1. NOTE:
    NOTE:If it is not possible to insert Special Tool 303-507, turn the crankshaft anti-clockwise back through approx. 20 degrees.
    Check the valve timing.
    • Turn the crankshaft clockwise two revolutions, and then through to TDC on cylinder no. 1.
    • Screw in Special Tool 303-507.
    • Carefully turn the crankshaft clockwise until the crankshaft web meets Special Tool 303-507.

  1. Check the timing by inserting the special tool.

  1. CAUTION:
    CAUTION:The timing pulley bolts can only be re-used once.
    NOTE:
    NOTE:Counterhold using the special tool.
    NOTE:
    NOTE:The crankshaft must remain at TDC on cylinder number 1.
    NOTE:
    NOTE:Only if Special Tool 303-376 cannot be inserted.
    Correct the valve timing.
    • If necessary mark the timing pulley bolts with paint. Renew any bolts that already have paint markings.
    • Loosen the camshaft timing pulley of the affected camshaft.
    • Turn the camshaft by the hexagon until it is possible to insert Special Tool 303-376.
    • Tighten the camshaft timing pulley.
    • Check the valve timing again.

  1. Install the spark plugs using the special tool.
Vehicles built from 08/1998
  1. Install the front engine mounting bracket.
All vehicles
  1. Locate the timing belt upper cover in position.
Vehicles built up to 07/1998
  1. Install the front engine mounting bracket.

  1. Install the front engine mounting.
Vehicles built from 08/1998
  1. Install the front engine mounting.
All vehicles
  1. Remove the workshop jack.
Vehicles built up to 07/1998
  1. Install the generator.
    1. Three bolts
    1. Connect the lead.
    1. Connect the plug.
Vehicles built from 08/1998
  1. Install the generator.
    1. Connect the plug.
    1. Attach the positive lead.
    1. Install the studs.
All vehicles
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove Special Tool and install the blanking plug.

  1. Screw in the bolts on the timing belt covers.
    1. Timing belt upper cover

  1. Install the coolant pump pulley and the drive belt idler pulley.
All vehicles
  1. Fit and tension the drive belt.

  1. Install the drive belt cover.
  1. Lower the vehicle.

  1. Install the coolant expansion tank.

  1. CAUTION:
    CAUTION:Use a blunt object (e.g. a plastic cable tie) to apply the silicone grease to avoid damaging the spark plug connector seals.
    CAUTION:
    CAUTION:Slide on the spark plug connector along the axis of the spark plug.
    NOTE:
    NOTE:Coat the inside of the spark plug connector with silicone grease to a depth of 5-10 mm.
    Install the cylinder head cover.
    1. Push on the spark plug connectors until they click in place.
    1. Install the three bolts for the upper timing belt cover.
    1. Screw on the nuts and tighten in two stages:

        2. 1. Stage 1: 3 Nm

        2. Stage 2: 10 Nm

  1. Install the cover plate on the cylinder head cover.
    1. Screw in the bolts.
    1. Push on the crankcase breather hose and close the wiring harness cover.
    • Screw on the oil filler cap.
  1. Standard finishing operations.
    • Secure the wiring as necessary using cable ties.

Exhaust Manifold > < Camshaft Seal