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Timing Belt: Installation

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: The camshaft must be held stationary at the hexagons with locking pliers. Do not use the alignment tool to hold the camshaft in position or damage to the camshaft may occur.
    NOTE: To loosen the camshaft pulleys, hold the camshafts by the hexagon.
    Fig 1: Removing Blanking Plug From Exhaust Camshaft Pulley
    G03430212Courtesy of FORD MOTOR CO.
  1. Loosen the camshaft pulleys.
    1. Remove the blanking plug from the exhaust camshaft pulley.
    2. Loosen the exhaust camshaft pulley bolt.
    3. Loosen the intake camshaft pulley bolt.
    2. NOTE: Rotate the camshafts clockwise as necessary.
    Fig 2: Positioning Camshaft Alignment Timing Tool
    G03430213Courtesy of FORD MOTOR CO.
  2. Install the camshaft alignment timing tool on the back of the camshafts.
    3. NOTE: Cylinder No. 1 is at top dead center (TDC) when the keyway is in the 12 o'clock position.
  3. Confirm the crankshaft position is at TDC (No. 1 cylinder) by rotating it clockwise against the alignment peg.
    4. CAUTION: Do not rotate the crankshaft; as necessary check that it is still resting against the timing pin.
    NOTE: The lug of the belt tensioner should not be hooked in the sheet metal cover during timing belt installation.
    Fig 3: Positioning Timing
    G03430214Courtesy of FORD MOTOR CO.
  4. Position a new timing belt in place.
    • Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension.
    5. NOTE: Incorrect timing belt tension will cause incorrect valve timing.
    Fig 4: Tightening Attaching Bolt
    G03430215Courtesy of FORD MOTOR CO.
  5. Pre-tension the timing belt.
    1. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover.
    2. Position the hex key slot in the tensioner adjusting washer to the 4 o'clock position.
    3. Tighten the attaching bolt enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 6 mm hex key.
    6. CAUTION: Tension the timing belt, working counterclockwise.
    Fig 5: Rotating Adjusting Washer Counterclockwise
    G03430216Courtesy of FORD MOTOR CO.
  6. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment).
  7. While holding the adjusting washer in position, tighten the bolt.
    Fig 6: Tightening Bolt
    G03430217Courtesy of FORD MOTOR CO.
    8. CAUTION: The camshaft must be held stationary at the hexagons with locking pliers. Do not use the alignment tool to hold the camshaft in position or damage to the camshaft may occur.
    Fig 7: Tightening Bolt On Intake Camshaft Sprocket
    G03430218Courtesy of FORD MOTOR CO.
  8. Tighten the bolt on the intake camshaft sprocket.
    9. CAUTION: The camshaft must be held stationary at the hexagons with locking pliers. Do not use the alignment tool to hold the camshaft in position or damage to the camshaft may occur.
    Fig 8: Tightening Bolt On Exhaust Camshaft Sprocket
    G03430219Courtesy of FORD MOTOR CO.
  9. Tighten the bolt on the exhaust camshaft sprocket in three stages.
    • Stage 1: Tighten the bolt to 50 Nm (36 lb-ft).
    • Stage 2: Remove the TDC peg and the camshaft alignment timing tool.
    • Stage 3: Tighten the bolt to 115-125 Nm (85-92 lb-ft).
    10. NOTE: Install a new oil plug seal.
    Fig 9: Installing Oil Plug Seal
    G03430220Courtesy of FORD MOTOR CO.
  10. Screw in the new oil plug on the variable camshaft timing assembly.
    11. NOTE: Turn the engine two turns in the normal direction of rotation by the crankshaft.
  11. Check the valve timing by inserting the special tools and correct the alignment as necessary.
    • Screw in special tool 303-574 and make sure that the crankshaft is resting against the special tool.
    • Insert special tool 303-465 into the camshafts. If necessary loosen the timing pulleys and correct the camshaft alignment.
    • Remove the special tools.
  12. Install the front engine mount lower bracket.
    Fig 10: Installing Front Engine Mount Lower Bracket
    G03430221Courtesy of FORD MOTOR CO.
  13. Install the accessory drive belt idler pulley.
    Fig 11: Installing Accessory Drive Belt Idler Pulley
    G03430222Courtesy of FORD MOTOR CO.
  14. Install the coolant pump pulley.
    • Hand-tighten the bolts.
    Fig 12: Installing Coolant Pump Pulley
    G03430223Courtesy of FORD MOTOR CO.
  15. Position the upper timing belt cover and install the bolts.
    Fig 13: Positioning Upper Timing Belt Cover
    G03430224Courtesy of FORD MOTOR CO.
  16. Install the studs.
    Fig 14: Installing Studs
    G03430225Courtesy of FORD MOTOR CO.
  17. Connect the knock sensor electrical connector to the upper timing belt cover.
    Fig 15: Connecting Knock Sensor Electrical Connector To Upper Timing Belt Cover
    G03430226Courtesy of FORD MOTOR CO.
  18. Install the engine mount upper bracket, the nuts and the bolt.
    Fig 16: Installing Engine Mount Upper Bracket
    G03430227Courtesy of FORD MOTOR CO.
  19. Attach the ground strap and install the nut.
    Fig 17: Attaching Ground Strap
    G03430228Courtesy of FORD MOTOR CO.
  20. Position the lower timing belt cover and install the bolts.
    Fig 18: Positioning Lower Timing Belt Cover
    G03430229Courtesy of FORD MOTOR CO.
  21. Position the crankshaft pulley and install the bolt.
    • Hand-tighten the bolt.
    Fig 19: Positioning Crankshaft Pulley
    G03430230Courtesy of FORD MOTOR CO.
  22. Rotate the tensioner and install the accessory drive belt.
    Fig 20: Installing Accessory Drive Belt
    G03430231Courtesy of FORD MOTOR CO.
  23. Tighten the crankshaft pulley bolt.
    Fig 21: Tightening Crankshaft Pulley Bolt
    G03430232Courtesy of FORD MOTOR CO.
  24. Tighten the coolant pump pulley bolts.
    Fig 22: Tightening Coolant Pump Pulley Bolts
    G03430233Courtesy of FORD MOTOR CO.
  25. Position the RH lower splash shield and install the bolts.
    Fig 23: Positioning RH Lower Splash Shield
    G03430234Courtesy of FORD MOTOR CO.
  26. Install the wheel and tire assembly.
  27. Install the stud.
    Fig 24: Installing Wheel & Tire Assembly
    G03430235Courtesy of FORD MOTOR CO.
  28. Install the coolant tube.
    Fig 25: Installing Coolant Tube
    G03430236Courtesy of FORD MOTOR CO.
  29. Install the catalytic converter.
  30. Inspect the valve cover gasket. Install a new gasket, if necessary.
  31. Position the valve cover.
    1. Install the studbolts.
    2. Install the bolts.
    Fig 26: Installing Studbolts
    G03430237Courtesy of FORD MOTOR CO.
  32. Connect the wiring harness anchors to the valve cover studs.
    Fig 27: Connecting Wiring Harness Anchors To Valve Cover Studs
    G03430238Courtesy of FORD MOTOR CO.
  33. Attach the catalyst monitor and heated oxygen sensor electrical connectors to the bracket. Connect the electrical connectors.
    Fig 28: Connecting Electrical Connectors
    G03430239Courtesy of FORD MOTOR CO.
  34. Connect the throttle cables.
    • Connect the accelerator cable.
    • If equipped, connect the speed control actuator cable.
    Fig 29: Connecting Speed Control Actuator Cable
    G03430240Courtesy of FORD MOTOR CO.
  35. Install the spark plugs.
  36. Install the air cleaner outlet pipe.
  37. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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