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Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) - Timing Belt Fiesta 2002.25 (11/2001-)
In-vehicle Repair

Special Tool(s)

Universal Flange Holding Wrench

205-072

Gauge, Bolt Angle

303-174

Alignment Plate, Camshaft

303-376B

Socket, Spark Plug

303-499

Locking Tool, Crankshaft

303-748

Locking Tool, Timing Belt Tensioner

303-1054

General Equipment
Trolley jack
Wooden block
Materials
Name
Specification
High-Temperature Grease
ESD-M1C220-A 

Removal

All vehicles
  1. Remove the valve cover.
    For additional information, refer to: Valve Cover (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair).

  1. Loosen the coolant pump pulley retaining bolts.
  1. Remove the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning (303-05 Accessory Drive, Removal and Installation).

  1. Remove the crankshaft pulley.

  1. Remove the coolant pump pulley.

  1. Remove the timing belt cover retaining bolts.
    1. Remove the timing belt upper cover retaining bolts.
    1. Remove the timing belt lower cover retaining bolts.
    • Remove the lower cover.
  1. Lower the vehicle.

  1. Detach the power steering fluid reservoir from the bracket and position it to one side.

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

  1. Disconnect the generator electrical connector.

  1. Detach the generator from the engine.
    1. Loosen the bolt.
    1. Remove the bolt.
    1. Remove the nut and the stud.
  1. CAUTION:
    CAUTION:Do not support the engine directly on the oil pan.
    Place the trolley jack with a wooden block under the engine and raise it slightly until the engine front mount is free from strain.

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

  1. Remove the timing belt upper cover.

  1. Remove the engine front mount bracket.

  1. Using the special tool, remove the spark plugs.
Engines with eccentric cam timing belt tensioner

  1. Slacken the timing belt tensioner and remove the timing belt.
    • Discard the timing belt.

  1. Remove the timing belt tensioner.
Engines with slotted bracket timing belt tensioner

  1. Remove the timing belt tensioner and the timing belt.
    • Discard the timing belt.
Vehicles built 09/2003 onwards

  1. Remove the timing belt.
    • Detension the timing belt and lock the timing belt tensioner with the special tool.
    • Discard the timing belt.

  1. Remove the timing belt tensioner.
Vehicles built 04/2005 onwards

  1. Remove the timing belt.
    • Detension the timing belt and lock the timing belt tensioner with the special tool.
    • Discard the timing belt.

Installation

All vehicles
  1. Set the crankshaft to approximately 20 degrees before TDC.

  1. CAUTION:
    CAUTION:Install a hose (order no. E890438S) to the special tool studs, to prevent damage to the camshaft pulleys.
    NOTE:
    NOTE:Make sure the camshaft pulleys turn on the camshafts.
    Loosen the camshaft pulley retaining bolts.
    • Discard the retaining bolts.

  1. Turn the camshafts to TDC on cylinder number 1 and install the special tool.

  1. Remove the blanking plug and install the special tool.
    • Carefully turn the crankshaft against the special tool.
  1. NOTE:
    NOTE:Install a new timing belt.
    NOTE:
    NOTE:Install the timing belt, beginning with the crankshaft timing pulley working counterclockwise.
    Install the timing belt.

  1. Measuring the depth of the threaded hole in the crankshaft.
    • Depth of the threaded = 42 mm: Use an M12x29 mm crankshaft pulley center bolt.
    • Depth of the threaded = 52 mm: Use an M12x44,5 mm crankshaft pulley center bolt.

  1. Attach the timing belt lower cover.

  1. NOTE:
    NOTE:Install a new crankshaft pulley retaining bolt.
    Install the crankshaft pulley.
    • Tighten the crankshaft pulley retaining bolt in two stages.
    • Stage 1: 45 Nm.
    • Stage 2: 90 degrees.
Engines with eccentric cam timing belt tensioner

  1. Install the timing belt tensioner.

  1. Tension the timing belt.
    • Tension the timing belt by turning the tensioner counterclockwise until the arrow points at the mark and tighten the bolt.
Engines with slotted bracket timing belt tensioner

  1. Install the timing belt tensioner and tension the timing belt.
    • Screw in the bolts finger tight.
    • Tension the timing belt by turning the tensioner clockwise until the arrow points in line with the center of the rectangular hole and tighten the bolt.
Vehicles built 09/2003 onwards

  1. WARNING:
    WARNING:Do not remove the special tool, until the timing belt is correctly positioned. Failure to follow this instruction may result in personal injury, or may damage the timing belt tensioner.
    Install the timing belt tensioner.

  1. Tension the timing belt.
    • Remove the special tool.
Vehicles built 04/2005 onwards

  1. WARNING:
    WARNING:Do not remove the special tool, until the timing belt is correctly positioned. Failure to follow this instruction may result in personal injury, or may damage the timing belt tensioner.
    Tension the timing belt.
    • Remove the special tool.
All vehicles

  1. CAUTION:
    CAUTION:Install a hose (order no. E890438S) to the special tool studs, to prevent damage to the camshaft pulleys.
    CAUTION:
    CAUTION:Do not tighten the camshaft pulley bolts against the timing plate.
    NOTE:
    NOTE:The camshafts must remain at TDC.
    NOTE:
    NOTE:Install new camshaft pulley retaining bolts.
    Using the special tool, tighten the camshaft pulleys.

  1. Remove special tool.

  1. Remove the special tool.
  1. NOTE:
    NOTE:Only turn the engine in its normal direction of rotation.
    Turn the engine two revolutions.

  1. Install the special tool.
    • Carefully turn the crankshaft against the special tool.

  1. Check the valve timing.
    • If necessary loosen the camshaft pulleys and correct the camshaft alignment.
    • Remove the special tool.

  1. Remove the special tool.

  1. Install the blanking plug.

  1. Using the special tool, install the spark plugs.
    • Apply grease to the spark plug threads.

  1. Install the engine front mount bracket.
    • Tighten the bolts in the indicated order in three stages.
    • Stage 1: Hand tighten bolt 1.
    • Stage 2: Tighten bolts 2 to 55 Nm.
    • Stage 3: Tighten bolt 3 to 55 Nm.

  1. Install the timing belt upper cover.

  1. NOTE:
    NOTE:Install new engine front mount retaining nuts.
    Install the engine front mount.
  1. Remove the trolley jack.

  1. Attach the generator.
    1. Install the stud and nut.
    1. Install the bolt.
    1. Tighten the bolt.

  1. Connect the generator electrical connector.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Install the timing belt upper cover retaining bolts.

  1. NOTE:
    NOTE:Do not tighten the coolant pump pulley retaining bolts at this stage.
    Install the coolant pump pulley.
  1. Install the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning (303-05 Accessory Drive, Removal and Installation).

  1. Tighten the coolant pump pulley retaining bolts.
  1. Install the valve cover.
    For additional information, refer to: Valve Cover (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair).

  1. Attach the power steering fluid reservoir to the bracket.

  1. Attach the coolant expansion tank to the bracket.

Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 1.25L Duratec-16V (Sigma)-1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma) > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Timing Belt

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