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Exhaust Manifold > < Camshaft Seal

Focus 1999 (08.1998-12.2004)

Engine - 1.4L/1.6L - Timing Belt Focus 1999 (08/1998-12/2004)
In-vehicle Repair

Special Tool(s)

Universal Flange Holding Wrench

205-072 (15030A)

Gauge, Bolt Angle

303-174 (21540)

Alignment Plate, Camshaft

303-376 (21162B)

Socket, Spark Plug

303-499 (21202)

Timing Peg, Crankshaft TDC

303-748
General Equipment
Trolley jack
Materials
Name
Specification
Cable ties
 
Lubricant (spark plug threads - Never Seeze)
ESE-M1244-A 
Silicone grease
ESE-M1C171-AA 

Removal

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

  1. Loosen the bolts on the coolant pump pulley.
  1. Remove the accessory drive belt. For additional information, refer to: (303-05 Accessory Drive)
    Accessory Drive Belt (Removal and Installation),
    Accessory Drive Belt - Vehicles Built Up To: 03/2002, Vehicles Without: Accessory Drive Belt Tensioner (Removal and Installation),
    Accessory Drive Belt - Vehicles Built From: 03/2002, Vehicles Without: Accessory Drive Belt Tensioner (Removal and Installation).

  1. Remove the crankshaft pulley/vibration damper.
    • Discard the bolt.

  1. Remove the coolant pump pulley and the drive belt idler pulley.

  1. Remove the bolts from the timing belt cover.
    1. Timing belt upper cover
    1. Timing belt lower cover
    • Remove the lower cover.
  1. Lower the vehicle.
  1. Remove the valve cover.
    For additional information, refer to: Valve Cover (303-01A Engine - 1.4L/1.6L, In-vehicle Repair).

  1. Remove the spark plugs using the special tool.

  1. Detach the coolant expansion tank.
    1. Remove the bolt.
    1. Unclip the coolant expansion tank and lay it to one side.

  1. Unclip the power steering reservoir and lay it to one side.

  1. Remove the generator and lay it to one side.
    1. Disconnect the plug.
    1. Disconnect the positive cable.
    1. Detach the generator.
    • Detach the studs.
  1. Place the trolley jack with a wooden block under the oil pan and raise it slightly until the front engine mounting is free from strain.

  1. Remove the engine mounting.
  1. Remove the timing belt upper cover.

  1. Remove the front engine mounting bracket (shown with engine removed).
Vehicles with eccentric cam timing belt tensioner
  1. Slacken and remove the timing belt (shown with engine removed).
    • Undo the bolt.
    • Discard the timing belt.
Vehicles with slotted bracket timing belt tensioner
  1. Slacken and remove the timing belt (shown with engine removed).
    • Undo the bolts.
    • Discard the timing belt.
Vehicles built 09/2003 onwards
  1. Remove the timing belt.
    • Tension the timing belt tensioner by pulling the timing belt and lock it with the special tool.
    • Discard the timing belt.

  1. Remove the timing belt tensioner.

Installation

All Vehicles
  1. Set the crankshaft to 20 degrees before TDC.

  1. CAUTION:
    CAUTION:Use the special tool to stop them from turning.
    Loosen the bolts until the camshaft timing pulleys can be turned on the camshafts.
    • Discard the retaining bolts.

  1. Turn the camshafts to TDC on cylinder number 1 and insert the special tool.
    • Turn the camshafts by the hexagon using a 21 mm open-ended spanner until the special tool can be inserted.
  1. NOTE:
    NOTE:Install a new timing belt.
    NOTE:
    NOTE:Install the timing belt, beginning with the crankshaft timing belt pulley working counterclockwise.
    Install the timing belt.

  1. Attach the lower timing belt cover (shown from below).

  1. NOTE:
    NOTE:If it is not possible to insert the special tool, turn back the crankshaft counter-clockwise by approx. 20 degrees.
    Turn the crankshaft to TDC on cylinder number 1.
    • Remove the blanking plug and screw in the special tool.
    • Carefully turn the crankshaft in a clockwise direction until the crank web touches the special tool.

  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: 40 Nm.
    • Stage 2: 90 degrees.
Vehicles with eccentric cam timing belt tensioner
  1. NOTE:
    NOTE:Install a new timing belt.
    NOTE:
    NOTE:Do not move the eccentric during tightening. Hold with an Allen key.
    Tension the timing belt (shown with engine removed).
    • Using a 6 mm Allen key, turn the eccentric counter-clockwise until the pointer is exactly in line with the centre of the rectangular hole.
    • Tighten the bolt.
Vehicles with slotted bracket timing belt tensioner
  1. NOTE:
    NOTE:Install a new timing belt.
    Tension the timing belt (shown with engine removed).
    • Use an 8 mm Allen key to tension until the pointer is exactly in line with the center of the rectangular hole.
    • Tighten the bolts.
Vehicles built 09/2003 onwards
  1. Install the timing belt tensioner.

  1. Tension the timing belt.
    • Remove the special tool.
All vehicles
  1. CAUTION:
    CAUTION:Do not tighten the camshaft timing pulleys against Special Tool 303-376.
    NOTE:
    NOTE:Do not turn the crankshaft and the camshaft.
    NOTE:
    NOTE:Install new camshaft pulley retaining bolts.
    Tighten the bolts of the camshaft timing pulleys.
  1. Remove Special Tool 303-376.

  1. Unscrew the special tool (shown from below).
  1. Check the valve timing.
    • Turn the crankshaft two turns clockwise and turn cylinder number 1 to TDC.
      NOTE:
      NOTE:If it is not possible to install Special Tool 303-748, turn back the crankshaft counter-clockwise through approx. 20 degrees.
    • Screw in Special Tool 303-748.
    • Carefully turn the crankshaft in a clockwise direction until the crank web touches Special Tool 303-748.

  1. Check the valve timing by inserting the special tool.

  1. NOTE:
    NOTE:Only if Special Tool 303-376 cannot be inserted.
    NOTE:
    NOTE:Counterhold using the special tool.
    NOTE:
    NOTE:The crankshaft must remain at TDC on cylinder number 1.
    Correct the valve timing.
    • Loosen the bolt of the affected camshaft.
    • Turn the camshaft by the hexagon until Special Tool 303-376 can be inserted.
    • Tighten the camshaft timing pulley.
    • Check the valve timing again in accordance with the previous steps.

  1. Install the spark plugs using the special tool.

  1. Install the front engine mounting bracket.
  1. Move the timing belt upper cover into position.

  1. Install the engine mounting.
  1. Remove the trolley jack.

  1. Install the generator.
    1. Attach the connector.
    1. Install the positive lead.
    • Install the studs.
    1. Install the generator.
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Unscrew Special Tool 303-748 and screw in the blanking plug.

  1. Install the bolts of the upper timing belt covers.

  1. Install the coolant pump pulley and the drive belt idler pulley.
  1. Install the accessory drive belt. For additional information, refer to: (303-05 Accessory Drive)
    Accessory Drive Belt (Removal and Installation),
    Accessory Drive Belt - Vehicles Built Up To: 03/2002, Vehicles Without: Accessory Drive Belt Tensioner (Removal and Installation),
    Accessory Drive Belt - Vehicles Built From: 03/2002, Vehicles Without: Accessory Drive Belt Tensioner (Removal and Installation).

  1. Clip on the power steering reservoir.

  1. Attach the coolant expansion tank.
    1. Clip in the expansion tank.
    1. Tighten the bolt.
  1. Install the valve cover.
    For additional information, refer to: Valve Cover (303-01A Engine - 1.4L/1.6L, In-vehicle Repair).
  1. Standard finishing operations.
    • Connect the battery negative lead.
      For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).

Exhaust Manifold > < Camshaft Seal