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Cylinder Head > < Timing Belt - Vehicles Built Up To: 04-2005

Focus 2004.75 (07.2004-)

Engine - 1.6L Duratec-16V Ti-VCT (Sigma) - Timing Belt—Vehicles Built From: 04/2005 Focus 2004.75 (07/2004-)
In-vehicle Repair

Special Tool(s)

Locking tool, flywheel

303-393

Adapter for 303-393

303-393-02

Locking Tool, Crankshaft

303-748

Locking tool, timing belt tensioner

303-1054

Locking Tool, Camshaft Adjustment Unit

303-1097
General Equipment
Trolley jack
WARNING:
WARNING:Never smoke or use any kind of naked flame when working on or near any fuel system components. Highly flammable vapors are always present which could ignite. Failure to observe this instruction can lead to personal injury.
  1. Detach the right-hand front wheel.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
  1. Remove the air cleaner.
    For additional information, refer to: Air Cleaner - 1.6L Duratec-16V Ti-VCT (Sigma) (303-12A Intake Air Distribution and Filtering, Removal and Installation).
  1. Remove the generator.
    For additional information, refer to: Generator - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (414-02 Generator and Regulator, Removal and Installation).
  1. Remove the starter motor.
    For additional information, refer to: Starter Motor - 1.6L Duratec-16V Ti-VCT (Sigma) (303-06A Starting System, Removal and Installation).

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

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

 
Item
Part Number
Description
1
-
Coolant pump pulley bolts
2
-
Timing belt cover retaining bolts
3
-
Crankshaft belt pulley
See Removal Detail
4
-
Timing belt cover, lower
See Removal Detail
5
-
Engine front mounting bracket retaining bolts
See Removal Detail
6
-
Timing Belt
See Removal Detail

7. Install the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Timing Belt
See Installation Detail
2
-
Timing belt cover, lower
See Installation Detail
3
-
Crankshaft belt pulley
See Installation Detail
4
-
Engine front mounting bracket retaining bolts
See Installation Detail
5
-
Timing belt cover retaining bolts
6
-
Coolant pump pulley bolts

Removal Details

Item 3 : Crankshaft belt pulley
  1. NOTE:
    NOTE:Only turn the crankshaft in the normal direction of rotation.
    Turn the crankshaft until the marking on the VCT unit is at the 11 o'clock position.
  1. Raise the vehicle on the lift. For additional information, refer to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  1. Remove the blanking plugs and install the special tool.
    • Carefully turn the crankshaft clockwise against the special tool.

  1. CAUTION:
    CAUTION:Make certain that the crankshaft is on the crankshaft locking tool.
    Using the special tool, lock the crankshaft in position.

  1. Remove the crankshaft pulley.
    • Discard the bolt.

Item 4 : Timing belt cover, lower
  1. Remove the lower timing belt cover.

Item 5 : Engine front mounting bracket retaining bolts

  1. Lower the vehicle.
  1. Position the workshop jack with a wooden block underneath the engine and raise the engine until the front engine mounting is no longer taking the weight.

  1. NOTE:
    NOTE:Discard the front engine mount nuts.
    NOTE:
    NOTE:Mark the installed position of the front engine mount.
    Remove the front engine mounting.

Item 6 : Timing Belt
  1. NOTE:
    NOTE:Scribed lines on the exhaust side and dot marks on the inlet side.
    Install the special tool.

  1. Tension the timing belt tensioner and secure with the special tool.
  1. Take off the timing belt.
    • Discard the timing belt.

Installation Details

Item 1 : Timing Belt

  1. NOTE:
    NOTE:Beginning at the VCT elements, fit the timing belt clockwise over the crankshaft timing belt pulley.
    Install the timing belt.

  1. CAUTION:
    CAUTION:Only remove the special tool once the timing belt is correctly laid in place. Failure to observe this instruction may lead to injury and/or component damage.
    Tension the timing belt.
    • Remove the special tool.

Item 2 : Timing belt cover, lower
  1. Measure the depth of the bore in the crankshaft.
    • Depth of bore = 42 mm: install M12 x 29 mm central bolt.
    • Depth of bore = 52 mm: install M12 x 44.5 mm central bolt.

  1. Install the timing belt lower cover.

Item 3 : Crankshaft belt pulley
  1. CAUTION:
    CAUTION:Counterhold the crankshaft pulley using the special tool.
    NOTE:
    NOTE:Install a new crankshaft pulley bolt.
    Install the crankshaft pulley.
    • Counterhold the crankshaft pulley using the special tool and tighten the crankshaft pulley bolt in two stages.
    • Stage 1: 45 Nm
    • Stage 2: 90 degrees

  1. Remove the special tool.

  1. Remove the special tool.

  1. Remove the special tool.

  1. NOTE:
    NOTE:Only turn the crankshaft in the normal direction of rotation.
    Turn the crankshaft about two revolutions until the marking on the VCT unit is at the 11 o'clock position.

  1. CAUTION:
    CAUTION:Make certain that the crankshaft is on the crankshaft locking tool.
    Install the special tool.
    • Carefully turn the crankshaft clockwise against the special tool.

  1. Install the special tool.
    • If the special tool cannot be installed, repeat the adjustment according to the preceding steps.

  1. Remove the special tool.

  1. Install the blanking plug

  1. Remove the special tool.

Item 4 : Engine front mounting bracket retaining bolts
  1. NOTE:
    NOTE:Install new front engine mounting nuts.
    Install the front engine mounting.

Cylinder Head > < Timing Belt - Vehicles Built Up To: 04-2005