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Exhaust Manifold > < Camshaft Seal

S-MAX.Galaxy 2006.5 (03.2006-)

Engine - 1.8L Duratorq-TDCi (Lynx) Diesel - Timing Belt S-MAX/Galaxy 2006.5 (03/2006-)
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
Cable ties
Trolley jack

Removal

  1. Disconnect the battery.
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Remove the following items:
    1. Refer to: Air Cleaner (303-12C Intake Air Distribution and Filtering - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).
    1. Refer to: Valve Cover (303-01D Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. Refer to: Fuel Filter (310-01C Fuel Tank and Lines - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. NOTE:
    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).
  1. Remove the front right wheel.
    Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

  1. Refer to: Accessory Drive Belt (303-05C Accessory Drive - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. Secure the air conditioning (A/C) compressor to one side.
    General Equipment: Cable ties
  1. Refer to: Starter Motor (303-06C Starting System - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. CAUTION:
    CAUTION:Make sure that the crankshaft is not rotated while the special tool is installed.
    CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    1. Remove the cylinder block blanking plug and
      Install the Special Tool(s): 303-193
    1. Install the Special Tool(s): 303-393

  1. Detach the charge air cooler outlet pipe and position it to one side.

  1. General Equipment: Trolley jack

  1. Special Tool(s): 303-376B

  1. Special Tool(s): 205-072

  1. Special Tool(s): 303-651

Installation
  1.  
    • Check the timing belt tensioner and make sure that the timing belt tensioner pointer rotates clockwise freely.
    • Move the timing belt tensioner adjustment arm to the 3 o'clock position.
    • Do not fully tighten the timing belt tensioner retaining bolt at this stage.

  1.  
    • The camshaft pulley must be able to rotate freely on the camshaft taper. Tighten the camshaft pulley bolt finger tight and then loosen by one-half turn.
    • Install the timing belt with the direction arrows in the direction of engine rotation.

  1. Tension the timing belt counterclockwise until the pointer is positioned between the sides of the window.
    Torque: 50 Nm

  1. Special Tool(s): 205-072
    Torque: 50 Nm
  1. Remove the Special Tool(s): 303-376B, 303-193, 303-393
  1.  
    1. Rotate the crankshaft 2 revolutions. Replace the Timing Peg just before TDC on the second revolution.
      Install the Special Tool(s): 303-193
    1. Rotate the crankshaft slowly until the crankshaft stops at TDC.
  1. Check that the timing belt tensioner pointer is positioned in the window, otherwise the timing belt tensioning steps must be repeated.

  1. NOTE:
    NOTE:If the special tool cannot be installed, the timing belt tensioning steps must be repeated.
    Install the Special Tool(s): 303-376B
  1. Remove all special tools and install the cylinder block blanking plug.
    Remove the Special Tool(s): 303-376B, 303-193, 303-393
    Torque: 23 Nm

  1. Torque: 7 Nm

  1.  
    1. Torque: 12 Nm
    1. Torque: 80 Nm
    1. NOTE:
      NOTE:Only tighten the bolts finger tight at this stage.

  1. Lower and remove the Trolley jack.
    General Equipment: Trolley jack

  1. Torque: 90 Nm

  1. Refer to: Starter Motor (303-06C Starting System - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. Torque: 25 Nm

  1. Torque:
    1 27 Nm
    2 10 Nm
  1. Refer to: Accessory Drive Belt (303-05C Accessory Drive - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1.  
    1. Torque: 35 Nm
    1. Loosen: 360°
    1. Torque: 85 Nm

  1. Install the front right wheel.
    Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

  1. Torque:
    1 7 Nm
    2 23 Nm
    3 23 Nm
  1. Refer to: Fuel Filter (310-01C Fuel Tank and Lines - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. Torque: 23 Nm
  1. Install the following items:
    1. Refer to: Valve Cover (303-01D Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).
    1. Refer to: Air Cleaner (303-12C Intake Air Distribution and Filtering - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).
  1. Connect the battery.
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Exhaust Manifold > < Camshaft Seal