| In-vehicle Repair Special Tool(s) | | Locking Tool, Flywheel 303-393 | | | Adapter for 303-393 303-393-01 | | | Remover/Installer, Hose Clamp 303-397 | | | Alignment Peg, Camshaft 303-735 | | | Alignment Peg, Crankshaft 303-1059 | | | Universal Flange Holding Wrench 205-072 | General Equipment CAUTION:Never install a used timing belt. CAUTION:Do not install the timing belt until the engine has cooled to workshop temperature. | | -
Remove the cowl panel grille.
For additional information, refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
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Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
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NOTE:The engine upper cover is held in place by three ball clips. The ball clips are not vertical, but are angled backwards by approximately 20 degrees. Location of the engine upper cover ball clips. | | | -
CAUTION:Contact of the engine upper cover with the cowl panel may cause damage (scratches) on the engine upper cover. If the ambient temperature is below 0°C, detach the engine upper cover with extreme caution. Failure to follow this instruction may cause the engine upper cover to be damaged. NOTE:Only remove and install the engine upper cover in the sequence shown. Remove the engine upper cover. - Detach the engine upper cover ball clips in the sequence shown.
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Remove the accessory drive belt.
For additional information, refer to: Accessory Drive Belt - 2.0L Duratorq-TDCi (DW) Diesel (303-05A Accessory Drive, Removal and Installation).
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Remove the starter motor.
For additional information, refer to: Starter Motor - 2.0L Duratorq-TDCi (DW) Diesel (303-06A Starting System, Removal and Installation).
| 8. Remove the components in the order indicated in the following illustration(s) and table(s). 7 - Crankshaft position (CKP) sensor electrical connector 8 - CKP sensor retaining bolt 10 - Timing belt lower cover retaining bolt 11 - Timing belt lower cover retaining nut 12 - Timing belt lower cover 14 - Timing belt tensioner retaining bolt 18 - Engine front mount retaining bolts 20 - Engine front mount bracket retaining bolts 21 - Engine front mount bracket 22 - Timing belt idler pulley All vehicles | | -
To install, reverse the removal procedure. | | | -
Apply soap solution to the ball clip mountings in the engine upper cover. - Soap solution, maximum concentration of soap in water 1:200.
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CAUTION:Contact of the engine upper cover with the cowl panel may cause damage (scratches) on the engine upper cover. Failure to follow this instruction may cause the engine upper cover to be damaged. Position the engine cover and clip it in place by pressing at the areas shown. - Make sure that the engine upper cover is fully engaged in the area of the fuel filter, if necessary apply more pressure in the areas shown.
| Vehicles with global closing | | -
Initialize the door window motors.
For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
| Removal Details Item 1 : Coolant expansion tank coolant hoses | | -
CAUTION:Protect the generator with lint free cloth to prevent dirt ingress. Using the special tool, remove the coolant expansion tank coolant hoses. - Using hose clamps, clamp the coolant hoses to prevent fluid loss.
- Allow the coolant to drain into a suitable container.
| Item 3 : Engine wiring harness | | -
Detach the engine wiring harness from the timing belt upper cover. | Item 4 : Timing belt upper cover | | -
Remove the timing belt upper cover. | Item 5 : Crankshaft pulley retaining bolt | | -
NOTE:Only rotate the crankshaft in the normal direction of rotation. Using the special tool, align the camshaft. - Turn the crankshaft until the alignment hole in the camshaft pulley is at the 4 o'clock position.
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Insert the special tool into the flywheel. | | | -
CAUTION:Make sure that the special tool engages correctly. Using the special tools, lock the flywheel. | | | -
NOTE:Do not discard the crankshaft pulley bolt at this stage. Remove the crankshaft pulley retaining bolt. | Item 13 : Crankshaft timing pulley | | -
NOTE:Do not touch the outer sensor ring. Remove the crankshaft timing pulley. | Item 17 : Engine front mount retaining nuts | | -
Using a trolley jack and a suitable wooden block under the oil pan raise the engine so that the engine front mount is free from load. | Installation Details Item 16 : Timing belt | | -
CAUTION:Install the timing belt with the direction arrows in the direction of crankshaft rotation. CAUTION:Do not install the timing belt until the engine has cooled to workshop temperature. NOTE:Install a new timing belt. Install the timing belt. | | | -
NOTE:Do not fully tighten the timing belt tensioner retaining bolt at this stage. NOTE:A new timing belt tensioner is supplied locked to aid installation. Install the timing belt tensioner. | | | -
NOTE:Install a new timing belt tensioner. NOTE:Use an Allen key to maintain tension on the timing belt tensioner until the retaining bolt is tightened. Unlock the timing belt tensioner and tension the timing belt. - Using an Allen key, turn the timing belt tensioner counterclockwise to increase the tension on the timing belt.
- Check that the pointer is positioned on the left-hand side of the window, if necessary increase the tension of the timing belt by turning the Allen key.
- Tighten the timing belt tensioner retaining bolt.
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CAUTION:Do not touch the outer sensor ring. Using the old crankshaft pulley retaining bolt, install the timing pulley and the crankshaft pulley. | | | -
Remove the special tools. | | | -
NOTE:Only rotate the crankshaft in the normal direction of rotation. Rotate the crankshaft four times. | | | -
Insert the special tool into the flywheel. | | | -
CAUTION:Make sure that the special tool engages correctly. Using the special tools, lock the flywheel. | | | -
NOTE:Only rotate the crankshaft in the normal direction of rotation. Using the special tool, align the camshaft. - If its not possible to install the special tool, repeat the previous steps.
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CAUTION:Do not touch the outer sensor ring. Remove the crankshaft pulley and the timing pulley. | | | -
NOTE:Use an Allen key to maintain tension until the timing belt tensioner retaining bolt is tightened. Using an Allen key, adjust the correct timing belt tension. - Using an Allen key, keep the timing belt tensioner adjustment arm in position.
- Loosen the timing belt tensioner retaining bolt.
- Tighten the timing belt tensioner retaining bolt when the pointer is positioned centrally in the window.
| Item 13 : Crankshaft timing pulley | | -
CAUTION:Do not touch the outer sensor ring. Install the timing pulley. | Item 5 : Crankshaft pulley retaining bolt | | -
NOTE:Install a new crankshaft pulley retaining bolt. Install the crankshaft pulley retaining bolt. - Tighten the crankshaft pulley retaining bolt in two stages.
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Remove the special tools. | Item 4 : Timing belt upper cover | | -
Install the timing belt upper cover. | Item 3 : Engine wiring harness | | -
Attach the engine wiring harness to the timing belt upper cover. | Item 1 : Coolant expansion tank coolant hoses | | -
Using the special tool, install the coolant expansion tank hoses. | | | -
Fill the coolant expansion tank with coolant. | |
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