Removal and Installation Special Tool(s) | 205-072 Universal Flange Holding Wrench | | 303-193 Timing Peg, Crankshaft TDC | | 303-376B Alignment Plate, Camshaft | | 303-393 Locking Tool, Flywheel | | 303-651 Remover, Camshaft Sprocket | General Equipment Removal | -
Disconnect the battery. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). | | - Remove the following items:
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Refer to: Air Cleaner (303-12E Intake Air Distribution and Filtering - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). -
Refer to: Valve Cover (303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation). | | -
Refer to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). | | -
NOTE:Only rotate the camshaft in the normal direction of rotation. Using the camshaft groove as a guide, rotate the crankshaft to 5 degrees before top dead center (TDC). | | -
Remove the front right wheel. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation). | | -
Refer to: Accessory Drive Belt (303-05D Accessory Drive - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation). | | -
Secure the air conditioning (A/C) compressor to one side. | | -
Refer to: Starter Motor (303-06D Starting System - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation). | | -
CAUTION:Make sure that the crankshaft is not rotated while the special tool is installed. CAUTION:Only rotate the crankshaft clockwise. -
Remove the cylinder block blanking plug and Install the Special Tool(s): 303-193 -
Install the Special Tool(s): 303-393 | | -
Detach the charge air cooler outlet pipe and position it to one side. | Installation | -
Tension the timing belt counterclockwise until the pointer is positioned between the sides of the window. Torque: 50 Nm | | -
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Rotate the crankshaft 2 revolutions. Replace the Timing Peg just before TDC on the second revolution. Install the Special Tool(s): 303-193 -
Rotate the crankshaft slowly until the crankshaft stops at TDC. | | -
Check that the timing belt tensioner pointer is positioned in the window, otherwise the timing belt tensioning steps must be repeated. | | -
NOTE:If the special tool cannot be installed, the timing belt tensioning steps must be repeated. | | -
Remove all special tools and install the cylinder block blanking plug. Torque: 23 Nm | | -
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NOTE:Only tighten the bolts finger tight at this stage. | | -
Lower and remove the Trolley jack. | | -
Refer to: Starter Motor (303-06D Starting System - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation). | | -
Refer to: Accessory Drive Belt (303-05D Accessory Drive - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation). | | -
Install the front right wheel. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation). | | -
Torque: 1 7 Nm 2 23 Nm 3 23 Nm | | -
Refer to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). | | - Install the following items:
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Refer to: Valve Cover (303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation). -
Refer to: Air Cleaner (303-12E Intake Air Distribution and Filtering - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). | | -
Connect the battery. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). | | |