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In-vehicle Repair|Oil Pan > < Camshaft Seal

Fiesta 2002.25 (11.2001-)

Engine - 1.4L Duratorq-TDCi (DV) Diesel - Timing Belt Fiesta 2002.25 (11/2001-)
In-vehicle Repair

Special Tool(s)

Alignment Peg, Crankshaft

303-732 (21-260)

Locking Tool, Crankshaft

303-734 (21-262)

Alignment Peg, Camshaft

303-735 (21-263)
General Equipment
Trolley jack
Wooden blocks

Removal

CAUTION:
CAUTION:Never install a used timing belt.
CAUTION:
CAUTION:Only install the timing belt after the engine has cooled to workshop temperature.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Drain the cooling system. For additional information, refer to Section  303-03A Engine Cooling / 303-03B Engine Cooling / 303-03C Engine Cooling / 303-03D Engine Cooling.
  1. Lower the vehicle.

  1. Disconnect the coolant degas hose from the coolant expansion tank.

  1. Detach the coolant expansion tank from the coolant expansion tank bracket and secure it to one side.

  1. Disconnect the fuel temperature sensor electrical connector.

  1. Detach the wiring harness from the timing belt upper cover.

  1. Remove the timing belt upper cover.
  1. Remove the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. CAUTION:
    CAUTION:Make sure that the special tool engages correctly.
    NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Using the special tool, lock the flywheel.
    • Turn the engine until the special tool fits into one of the slots in the flywheel.

  1. Remove the crankshaft pulley.

  1. Remove the special tool.

  1. Detach the crankshaft speed sensor wiring harness from the timing belt lower cover.

  1. Remove the timing belt lower cover.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Install the crankshaft pulley retaining bolt.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Using the special tool, align the camshaft.
    • Turn the engine until the alignment hole in the camshaft pulley is at the 2 o'clock position.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the timing belt guide.

  1. Remove the timing belt tensioner.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Remove the crankshaft timing belt pulley.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:Do not support the engine directly on the oil pan.
    Using a trolley jack with suitable wooden blocks support the engine.

  1. Detach the power steering fluid reservoir from the radiator grille opening panel and position it to one side.

  1. Remove the special tool.

  1. Remove the engine front mount.
    • Discard the nuts.

  1. Remove the engine front mount bracket.
  1. Remove the timing belt.
    • Discard the timing belt.

Installation
  1. NOTE:
    NOTE:Do not tighten the timing belt tensioner retaining bolt at this stage.
    Install the timing belt tensioner.
  1. CAUTION:
    CAUTION:Never install a used timing belt.
    CAUTION:
    CAUTION:Install the timing belt with the direction arrows in the direction of engine rotation.
    CAUTION:
    CAUTION:Only install the timing belt after the engine has cooled to workshop temperature.
    NOTE:
    NOTE:Install a new timing belt.
    Install the timing belt.

  1. Install the engine front mount bracket.

  1. NOTE:
    NOTE:Install new engine front mount retaining nuts.
    Install the engine front mount.

  1. Attach the power steering fluid reservoir to the radiator grille opening panel.

  1. Using the special tool, align the high pressure fuel pump pulley (engine shown removed for clarity) .
    • If there is no hole in the high pressure fuel pump bracket to install the special tool go to the next step.

  1. Make sure the high pressure fuel pump alignment holes are in line (engine shown removed for clarity).

  1. Remove the special tool from the high pressure fuel pump pulley (engine shown removed for clarity).

  1. Make sure the camshaft alignment holes are in line.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Check the correct position of the crankshaft timing belt pulley Woodruff key.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    NOTE:
    NOTE:Install the old crankshaft pulley bolt.
    NOTE:
    NOTE:Do not tighten the crankshaft pulley bolt at this stage.
    Install the crankshaft timing belt pulley.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Using the special tool, align the crankshaft.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Using an allen key, maintain tension until the timing belt tensioner bolt is tightened.
    Tension the timing belt (engine shown removed for clarity).
    1. Turn the timing belt tensioner adjustment arm counterclockwise to tension the timing belt slightly.
    1. The pointer must be positioned between the sides of the window.
    1. Tighten the timing belt tensioner retaining bolt.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Remove the special tool from the crankshaft timing belt pulley.

  1. Install the timing belt guide.

  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine ten revolutions.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Using the special tool, align the crankshaft.
  1. Lower the vehicle.

  1. Install the special tool.
    • If the special tool cannot be installed, repeat the previous steps.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Remove the special tool from the crankshaft timing belt pulley.

  1. Install the special tool (engine shown removed for clarity) .
    • If there is no hole in the high pressure fuel pump bracket to install the special tool go to the next step.

  1. Check that the high pressure fuel pump alignment holes are in line (engine shown removed for clarity).
    • If the alignment holes are not in line, repeat the previous steps.

  1. Remove the special tool (engine shown removed for clarity).

  1. Remove the special tool.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. CAUTION:
    CAUTION:Do not touch the outer sensor ring.
    Remove the crankshaft pulley retaining bolt.
    • Discard the bolt.

  1. Install the timing belt lower cover.

  1. Attach the crankshaft speed sensor wiring harness to the timing belt lower cover.

  1. CAUTION:
    CAUTION:Make sure the special tool engages correctly.
    NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Using the special tool, lock the flywheel.
    • Turn the engine until the special tool aligns with one of the slots in the flywheel.

  1. NOTE:
    NOTE:Install a new crankshaft pulley retaining bolt.
    Install the crankshaft pulley.
    • Tighten the crankshaft pulley bolt in two stages.
    • Stage 1: 30 Nm.
    • Stage 2: 180 degrees.

  1. Remove the special tool from the flywheel.
  1. Install the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. Install the timing belt upper cover.

  1. Attach the wiring harness to the timing belt upper cover.

  1. Connect the fuel temperature sensor electrical connector.

  1. Attach the coolant expansion tank to the coolant expansion tank bracket.

  1. Connect the coolant degas hose to the coolant expansion tank.
  1. Fill and bleed the cooling system. For additional information, refer to Section  303-03A Engine Cooling / 303-03B Engine Cooling / 303-03C Engine Cooling / 303-03D Engine Cooling.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

In-vehicle Repair|Oil Pan > < Camshaft Seal