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ford Workshop Repair Guides


Mondeo 1997 (08.1996-09.2000)

Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 1.8L Diesel > Description and Operation > General Procedures > In-vehicle Repair > Timing Belt - Vehicles With: Automatic Timing Belt Tensioner

Engine - 1.8L Diesel - Timing Belt—Vehicles With: Automatic Timing Belt Tensioner Mondeo 1997 (08/1996-09/2000)
In-vehicle Repair

Special Tool(s)

Universal flange holding wrench

205-07 (15-030A)

Subframe locating pins

205-316 (15097A)

Timing pin, crankshaft TDC position

303-193 (21-104)

Engine support bar

303-290 (21-140)

Adapter for

303-290 (21-140) 303-290-01 (21-140-01)

Alignment tool, camshaft alignment

303-376 (21-162B)

Gauge, powertrain alignment

502-003 (21-172)

Timing pin, injection pump timing

310-018 (23-019)

Radiator hose clamp remover/installer

303-397 (34-003)

General Equipment
Engine lifting eye (part no. V86HF 17A084 AA; drill out lower hole to 11 mm dia.)
Soft metal drift
Materials
Name
Specification
Cable ties
 
Coolant
ESDM-97B49-A 
Engine oil 5W-40
WSS-M2C912-A1 

Removal

All Vehicles
  1. General Notes.
    • In production, vehicles have been fitted with both automatic and mechanical camshaft timing belt tensioners.
      CAUTION:
      CAUTION:Only perform work on the timing belt when the engine has reached the ambient temperature of the workshop.
      NOTE:
      NOTE:Always renew the injection pump timing belt when renewing the camshaft timing belt.
    • Coolant pumps and timing belt tensioners with different idler pulleys have been fitted in production on vehicles with a mechanical timing belt tensioner. In service there are now only coolant pumps with two edges on the idler pulley available. When renewing the timing belt tensioner make sure that if the timing belt tensioner does not have an edge on the idler pulley it is not matched with a coolant pump without edges on the idler pulley. It is NOT permissible to convert from a mechanical to an automatic timing belt tensioner.
    • The locations of engine mountings and engine roll restrictors are described looking from the transmission to the engine.
    • Use Special Tool 303-397 (24-003) as required when removing and installing coolant and ventilation hoses.
    • If necessary, cut the cable ties and renew them on installation.
  1. Standard preparatory measures.
    • Make a note of the radio keycode.
    • Make a note of the pre-set radio stations.
      CAUTION:
      CAUTION:Disconnect the battery ground lead.
    • Open up the coolant expansion tank.
    • Slacken the wheel nuts of the front right-hand wheel.
  1. Raise the vehicle.
    • Remove the front right-hand wheel.

  1. Detach the engine undershield (nine self-tapping screws).

  1. Detach the lower radiator cover.
    1. Unscrew the bolts.
    1. Unhook the radiator cover from the radiator crossmember.

  1. NOTE:
    NOTE:After draining the coolant, re-tighten the coolant drain plug to 23 Nm.
    Drain off the coolant.

  1. NOTE:
    NOTE:It should be possible to insert the guide pins into the subframe and the body locating holes free of stress, otherwise the subframe must be realigned.
    Check the position of the subframe.

  1. Remove the front engine roll restrictor.
    1. Unscrew the center bolt.
    1. Detach the engine roll restrictor from the subframe.

  1. NOTE:
    NOTE:It must be possible to fit the gauge free of stress, otherwise the engine/transmission assembly must be realigned.
    Fit the gauge in the place of the engine roll restrictor.
    1. Attach the special tool to the subframe.
    1. Fit the center bolt.

  1. Detach the right-hand wheel arch trim panel.
Vehicles with air conditioning

  1. Remove the drive belt of the air conditioning compressor.
    1. Slacken the tensioning bolt.
    1. Take off the drive belt.

  1. Remove the generator drive belt.
    1. Slacken the bolt.
    1. Slacken the drive belt using the adjusting bolt and remove it.

  1. Remove the lower timing belt cover.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Close off the turbocharger opening with a clean, lint-free cloth.
    Remove the intercooler.
    1. Undo the two bolts on each side.
    1. Disconnect the hose.
    1. Unclip the low pressure hose.

  1. Disconnect the coolant pipe from the coolant expansion tank and disconnect the fuel return pipe.

  1. Disconnect the coolant hoses and the exhaust gas recirculation (EGR) hose.
    • Move the coolant hoses towards the hood.

  1. Disconnect the starter motor (two plugs and one nut).

  1. Attach the drilled out engine lifting eye .

  1. NOTE:
    NOTE:The spindle must take up the load.
    Attach the engine support bar.

  1. Remove the power steering pump cover.
    1. Undo the two bolts.
    1. Slacken the power steering pump bolt.

  1. Remove the power steering pump drive belt tensioner.
    1. Release the bolt.
    1. Slacken the drive belt using the adjusting bolt.
    1. Detach the tensioner.

  1. Take off the drive belt and detach the power steering pump.
    • Tie up the power steering pump.

  1. Detach the front engine mounting bracket.

  1. Detach the coolant expansion tank.
    • Lay the coolant expansion tank to one side.

  1. Remove the front engine mounting.

  1. Remove the injection pump belt pulley and disconnect the coolant hose from the coolant pump.

  1. Remove the upper timing belt cover.
    • Undo the three clips and remove the bolt.
    • Lift out the cover to the top.

  1. Detach the PCV hoses.
    1. Leading to the cylinder block.
    1. Leading to the turbocharger.

  1. Detach the cylinder head cover.
    • Remove the gasket.

  1. Turn the crankshaft to approx. TDC.
      NOTE:
      NOTE:Turn the engine in the normal direction of rotation.
    • Turn the crankshaft in the normal direction of rotation until the slot in the injection pump timing pulley is at 11 o'clock.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Turn the crankshaft to TDC.
    • Unscrew the blanking plug from the cylinder block.
      NOTE:
      NOTE:The timing pin must be screwed in as far as its stop.
    • Screw in the timing pin.
    • Carefully turn the crankshaft in the normal direction of rotation until it rests against the timing pin.
  1. Lower the vehicle.

  1. Slacken the bolt of the adjusting cam.
    • Turn the adjusting cam to 6 o'clock.

  1. NOTE:
    NOTE:If necessary, turn the camshaft using water pump pliers until the timing tool can be inserted.
    Insert the timing tool in the camshaft groove.

  1. Loosen the camshaft timing pulley.

  1. NOTE:
    NOTE:Insert a screwdriver between the camshaft timing pulley and the rear timing belt cover.
    Detach the camshaft timing pulley.
    • Free the camshaft timing pulley from the taper by striking it lightly with a soft metal drift .

  1. Remove the camshaft timing belt.
    • Detach the camshaft timing pulley and take it off with the camshaft timing belt.
    • Discard the timing belt.
Engines with an mechanical timing belt tensioner

  1. Turn the crankshaft to approx. TDC.
      NOTE:
      NOTE:Turn the engine in the normal direction of rotation.
    • Turn the crankshaft in the normal direction of rotation until the slot on the injection pump timing pulley is at 11 o'clock.
    • Coolant pumps and timing belt tensioners with different idler pulleys have been fitted in production on vehicles with a mechanical timing belt tensioner. In service there are now only coolant pumps with two edges on the idler pulley available. When renewing the timing belt tensioner make sure that if the timing belt tensioner does not have an edge on the idler pulley it is not matched with a coolant pump without edges on the idler pulley. It is NOT permissible to convert from a mechanical to an automatic timing belt tensioner.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Turn the crankshaft to TDC.
    • Unscrew the blanking plug from the cylinder block.
      NOTE:
      NOTE:The timing pin must be screwed in as far as its stop.
    • Screw in the timing pin.
    • Carefully turn the crankshaft in the normal direction of rotation until it rests against the timing pin.
  1. Lower the vehicle.

  1. Insert the timing pin into the camshaft timing pulley.
  1. Slacken the bolt of the camshaft timing pulley.

  1. Remove the camshaft timing belt.
    1. Undo the timing belt tensioner locking bolt.
    1. Slacken the timing belt tensioner by compressing the spring with water pump pliers.
    • Tighten the timing belt tensioner locking bolt.
    • Take off the timing belt and discard it.

Installation

Engines with an automatic timing belt tensioner

  1. CAUTION:
    CAUTION:Only perform work on the timing belt at workshop temperature.
    NOTE:
    NOTE:Always renew the camshaft timing belt and the injection pump timing belt.
    NOTE:
    NOTE:The crankshaft must be resting on the timing pin and the special tool must be inserted into the camshaft.
    NOTE:
    NOTE:Running direction of the timing belt (arrows). Make sure that the timing belt is properly centered on all of the timing pulleys.
    NOTE:
    NOTE:Lubricate the bolt contact face with engine oil.
    NOTE:
    NOTE:Check that the camshaft timing pulley is still free to turn on the camshaft.
    Lay a new camshaft timing belt in place.
    1. Fit the camshaft timing belt.
    1. Locate the camshaft timing pulley and the camshaft timing belt in installation position. Tighten the camshaft timing pulley bolt finger tight and then undo it a quarter turn.

  1. Pretension the camshaft timing belt.
      NOTE:
      NOTE:Coat the bolt contact surface of the adjusting cam with engine oil.
    • Turn the adjusting cam clockwise to the o'clock position and tighten the center bolt on the adjusting cam.

  1. NOTE:
    NOTE:Hold the camshaft timing pulley with Special Tool 15-030A.
    Tighten the bolt of the camshaft timing pulley.
  1. CAUTION:
    CAUTION:Remove the special tools.
    Turn the crankshaft six turns in the normal direction of rotation to settle the timing belt.

  1. Preparations for tensioning the timing belt.
    • Turn the crankshaft in the normal direction of rotation until the slot in the injection pump timing pulley is at 11 o'clock.
      NOTE:
      NOTE:The timing pin must be screwed in as far as its stop.
    • Screw in the timing pin.
    • Carefully turn the crankshaft in the normal direction of rotation until it rests against the timing pin.

  1. Undo the bolt on the adjusting cam half a turn.

  1. NOTE:
    NOTE:If necessary, turn the camshaft using water pump pliers until the timing tool can be inserted.
    Insert the timing tool in the camshaft groove.

  1. NOTE:
    NOTE:Hold the camshaft timing pulley with the special tool.
    Undo the camshaft timing pulley bolt three turns.

  1. NOTE:
    NOTE:Insert a screwdriver between the camshaft timing pulley and the rear timing belt cover.
    Remove the camshaft timing pulley.
    • Free the camshaft from the taper by striking it lightly with a soft metal drift .

  1. NOTE:
    NOTE:Check that the camshaft timing pulley is still free to turn on the camshaft.
    Tighten the camshaft timing pulley bolt finger tight and then undo it half a turn.

  1. NOTE:
    NOTE:Use a mirror to get a better view.
    Tension the camshaft timing belt.
      NOTE:
      NOTE:The adjustment range of the adjusting cam is between 6 o'clock (MIN) and 12 o'clock (MAX).
    • Tension the camshaft timing belt clockwise via the Allen screw on the adjusting cam until the pointer on the automatic camshaft timing belt tensioner appears in the right-hand corner of the adjustment range.

  1. NOTE:
    NOTE:Use the Allen screw on the adjusting cam to prevent the adjusting cam from turning.
    Evenly tighten the bolt on the adjusting cam.

  1. Checking the position of the automatic camshaft timing belt tensioner.
    • If the pointer is in range A: proceed to the next step.
      CAUTION:
      CAUTION:To avoid engine damage make sure that the pointer is within range A.
    • If the pointer is not in range A: repeat steps 11 and 12.

  1. NOTE:
    NOTE:Hold the camshaft timing pulley.
    Tighten the bolt of the camshaft timing pulley.
    • Tightening torque for M8 bolt: 35 Nm.
    • Tightening torque for M10 bolt: 48 Nm.

  1. Checking the position of the automatic timing belt tensioner.
    • If the pointer is in range A: proceed to the next step.
      CAUTION:
      CAUTION:To avoid engine damage make sure that the pointer is within range A.
    • If the pointer is not in range A: repeat the adjustment from step 8.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.
  1. Remove the special tools.
  1. Turn the crankshaft six turns in the normal direction of rotation.

  1. Checking the valve timing.
    • Turn the crankshaft in the normal direction of rotation until the slot on the camshaft timing pulley is at 11 o'clock.
      NOTE:
      NOTE:The timing pin must be screwed in as far as its stop.
    • Screw in the timing pin.
    • Carefully turn the crankshaft in the normal direction of rotation until it rests against the timing pin.

  1. Checking the position of the automatic timing belt tensioner.
    • If the pointer is in range A: proceed to the next step.
      CAUTION:
      CAUTION:To avoid engine damage make sure that the pointer is within range 'A'.
    • If the pointer is not in range A: repeat the adjustment from step 8.

  1. Insert the timing tool in the camshaft groove. If it is not possible to insert the alignment tool into the slot on the camshaft, repeat the adjustment from step 8.
  1. Remove the special tools and tighten the blanking plug to 24 Nm.
Engines with a mechanical timing belt tensioner

  1. CAUTION:
    CAUTION:Always renew the camshaft timing belt and the injection pump timing belt.
    CAUTION:
    CAUTION:The crankshaft must be resting on the timing pin and the alignment tool must be inserted into the camshaft timing pulley.
    NOTE:
    NOTE:Installation position of the timing belt tensioner spring and the injection pump spring. Do NOT mix up the springs.
    NOTE:
    NOTE:Check the running direction of the belt and make sure it is properly seated.
    NOTE:
    NOTE:Slots. The bolts on the camshaft timing pulley must be centered.
    Lay a new camshaft timing belt in place.
    • Lay the timing belt in place with the slack side towards the timing belt tensioner.
    • Undo the locking bolt on the timing belt tensioner and let the timing belt tensioner snap onto the timing belt.
    1. Tighten the timing belt tensioner locking bolt.
    1. Tighten the bolts on the camshaft timing pulley.

  1. Preparations for tensioning the timing belt.
      CAUTION:
      CAUTION:Remove Special Tools 303-193 (21-104) and 310-018 (23-019).
    • Turn the crankshaft six turns in the normal direction of rotation.
    1. Screw in the timing pin.
    • Carefully turn the crankshaft in the normal direction of rotation until it rests against the timing pin.
    1. It must be possible to insert the timing pin into the camshaft timing pulley.
    1. Undo the bolt on the camshaft timing pulley.

  1. CAUTION:
    CAUTION:It is not permitted to re-tension used timing belts.
    Tension the timing belt.
    • Undo the bolts on the camshaft timing belt tensioner a quarter turn so that the timing belt tensioner presses against the timing belt.
      NOTE:
      NOTE:All timing pins must be correctly inserted. The crankshaft must be resting against the timing pin.
    1. Tighten the bolts on the camshaft timing belt tensioner.
    1. Tighten the bolts on the camshaft timing pulley.
    1. Remove the timing pin.
    1. Unscrew the timing pin and tighten the blanking plug to 24 Nm.
All vehicles

  1. NOTE:
    NOTE:Clean and inspect the gasket and renew it if necessary (it can be reused several times).
    Attach the cylinder head cover.
    • Coat the gasket with engine oil prior to installation.

  1. Attach the PCV hoses.
    1. Leading to the cylinder block.
    1. Leading to the turbocharger.

  1. Fit the upper timing belt cover.
    • Bring the cover into position from above.
    • Fit the three clips and tighten the bolt.

  1. NOTE:
    NOTE:Fit the belt pulley and lower bolt at the same time.
    Fit the injection pump belt pulley and connect the coolant hose to the coolant pump.

  1. Fit the front engine mounting.

  1. NOTE:
    NOTE:Fit new nuts. Do not install the engine mounting bracket under stress. If necessary, lower the engine on the engine lifting bracket far enough for the bracket to be fitted without stress.
    Attach the front engine mounting bracket.

  1. Fit the coolant expansion tank.

  1. Fit the power steering pump and the drive belt.

  1. Fit the power steering pump drive belt tensioner.
    1. Attach the tensioner to the timing cover.
    1. Tension the drive belt using the adjusting bolt.
    1. Tighten the bolt.

  1. Fit the power steering pump cover.

  1. Detach the engine support bar.
    • Detach the engine lifting eye.

  1. Connect the starter motor (two plugs and one nut).

  1. Connect the coolant hoses and the EGR hose.

  1. Attach the coolant pipe to the coolant expansion tank and connect the fuel return pipe.

  1. Install the intercooler.
    1. Clip the low pressure hose in place.
    1. Connect the hose.
    1. Screw in the two bolts on each side.
  1. Raise the vehicle.

  1. Fit the lower timing belt cover.

  1. Fit the generator drive belt.
    1. Fit the drive belt and tension it with the adjusting bolt.
    1. Check the drive belt tension.
      • 1. 1 - 2 mm for new drive belts

        2. 2 - 4 mm for used drive belts

    1. Secure the idler pulley.
Vehicles with air conditioning

  1. Fit the drive belt of the air conditioning compressor.
    • Fit the drive belt.
    1. Tension it with the idler pulley.
    1. Check the drive belt tension:
      • 1. 1 - 2 mm for new drive belts

        2. 2 - 4 mm for used drive belts

  1. NOTE:
    NOTE:Do not skew the engine roll restrictor.
    Attach the front engine roll restrictor.
    • Remove the gauge.
    • Position the bolts.
    1. Tighten the two bolts.
    1. Tighten the center bolt.

  1. Fit the right-hand wheel arch trim panel.

  1. Fit the lower radiator cover.
    1. Hook the radiator cover into the radiator crossmember.
    1. Screw in the bolts.
  1. Standard finishing operations.
    • Check the routing of the wiring and hoses and secure them with cable ties if necessary.
    • Connect the battery ground lead.
    • Enter the radio keycode.
    • Reprogram the pre-set radio stations.
    • Reset the clock.
    • Carry out a road test to enable the PCM to gather data.
    • Check the fluid levels again and correct as necessary.
  1. Raise the vehicle.
    • Check the engine for leaks (visual inspection).

  1. Attach the engine undershield.
    • Hook the radiator cover into the radiator crossmember.
    1. Fit the bolts.
  1. Lower the vehicle.

Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 1.8L Diesel > Description and Operation > General Procedures > In-vehicle Repair > Timing Belt - Vehicles With: Automatic Timing Belt Tensioner

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