Friday, October 28, 2011

Replacing Timing Belt Tensioner on 2003 Ford Focus?


Timing Belt & Tensioner



Removal & Installation



2.0L (VIN 3) Engine
  1. Remove or disconnect the following:

    Negative battery cable
    Spark plugs
    Catalytic converter
    Right front wheel
    Right inner splash shield
    Accessory drive belt and idler pulley
  2. Rotate the crankshaft to Top Dead Center (TDC) and install Crankshaft TDC Timing Peg T97P-6000-A.
  3. Rotate the crankshaft clockwise against the peg.
  4. Remove or disconnect the following:

    Water pump pulley
    Valve cover
    Crankshaft pulley
    Timing belt covers
  5. Install Camshaft Alignment Timing Tool T94P-6256-CH into the slots of both camshafts at the rear of the cylinder head to lock the camshafts into position.
  6. Loosen the timing belt tensioner bolt and relieve the tension on the timing belt by disconnecting the tensioner tab from the timing cover back plate.
  7. Remove the timing belt.

    Click image to see an enlarged view
    Fig. Crankshaft alignment position-Ford 2.0L (VIN 3) engines


    Click image to see an enlarged view
    Fig. Placement of Camshaft Alignment Timing Tool T94P-6256-CH-Ford 2.0L (VIN 3) engines


    Click image to see an enlarged view
    Fig. Timing belt tensioner index marks-Ford 2.0L (VIN 3) engines
To install:

NOTE
Always replace the timing belt after loosening or removing it.

  1. Install the timing belt.
  2. Engage the timing belt tensioner tab into the timing cover back plate.
  3. Adjust the timing belt tensioner until the index marks are aligned. Tighten the tensioner bolt to 17-20 ft. lbs. (22-28 Nm).
  4. Remove the camshaft alignment tool and the crankshaft TDC peg.
  5. Install or connect the following:

    Timing belt covers
    Crankshaft pulley. Tighten the bolt to 81-89 ft. lbs. (110-120 Nm).
    Valve cover
    Water pump pulley
    Accessory drive belt and idler pulley
    Right inner splash shield
    Right front wheel
    Catalytic converter
    Spark plugs
    Negative battery cable
  6. Start the engine and check for proper operation.
2.0L (VIN 5) Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Raise and support the vehicle.
  4. Detach the drive belt cover.
  5. Loosen the coolant pump pulley retaining bolts.
  6. Remove the accessory drive belt.
  7. Remove the crankshaft pulley.
  8. Remove the accessory drive belt idler pulley.
  9. Remove the coolant pump pulley.
  10. Detach the timing belt lower cover.
  11. Lower the vehicle.
  12. Detach the coolant expansion tank and position it to one side.
  13. Detach the power steering fluid reservoir and position it to one side.
  14. Position the trolley jack with the wooden block under the oil pan and raise the engine so that the engine front mount is free from load.
    NOTE
    Mark the position of the engine front mount.
  15. Remove the engine front mount.
  16. Detach the timing belt upper cover. Leave the timing belt cover in its installed position.
  17. Remove the engine front mount bracket.
  18. Remove the timing belt upper cover.
  19. Remove the electronic ignition (EI) coil cover.
  20. Remove the engine upper cover.
  21. Disconnect the variable cam timing (VCT) valve electrical connector.
    NOTE
    Loosening sequence: from the outside to the inside, working diagonally.
  22. Disconnect the spark plug connectors.
  23. Detach the positive crankcase ventilation (PCV) hose.
  24. Remove the valve cover.
  25. Remove the spark plugs.
  26. Turn the engine to TDC on cylinder number 1.
  27. Loosen the timing belt tensioner bolt four turns.
  28. Position the tensioner so that the locating tab is at approximately the 4 o'clock position.
  29. Line up the hexagonal key slot in the tensioner adjusting washer with the pointer that is located behind the pulley.
  30. Remove the timing belt.
    NOTE
    Use an open ended wrench to prevent the camshaft from rotating.
  31. Remove the intake camshaft pulley blanking plug.
  32. Loosen the camshaft pulley retaining bolts.
To install:

NOTE
The camshaft timing pulleys must be able to turn freely on the camshafts.

  1. Turn the camshafts to the ignition position on cylinder No. 1 and insert the special tool Camshaft Alignment Plate 303-574 into the camshafts.

    Click image to see an enlarged view
    Fig. Camshaft Alignment Tool 303-574 installation-2.0L (VIN 5) engine
  2. Rotate the crankshaft to TDC on cylinder No. 1.

    Click image to see an enlarged view
    Fig. Set the crankshaft to Top Dead Center (TDC)-2.0L (VIN 5) engine
  3. Remove the blanking plug and install the Crankshaft TDC Timing Peg 303-574.

    Click image to see an enlarged view
    Fig. Installation of the Crankshaft TDC Timing Peg-2.0L (VIN 5) engine
  4. Starting from the crankshaft timing belt pulley and working counterclockwise install the timing belt, keeping it under tension.
    CAUTION
    Incorrect timing belt tension will result in incorrect valve timing.
  5. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover.
  6. Position the hexagonal key slot in the tensioner adjusting washer to the 4 o'clock position.
  7. 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 hexagonal key.
    CAUTION
    Tension the timing belt working counterclockwise.



    Click image to see an enlarged view
    Fig. Tensioner locating tab (1), hexagonal key slot (2) and attaching bolt (3)-2.0L (VIN 5) engine
  8. Using the hexagonal 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).

    Click image to see an enlarged view
    Fig. Adjusting the timing belt tensioner-2.0L (VIN 5) engine
  9. Tighten the bolt to 18 ft. lbs. (25 Nm), while holding the adjusting washer in position.
  10. Use an open ended wrench to prevent the camshaft from rotating and tighten the camshaft pulley retaining bolts. Tighten the intake pulley bolt to 88 ft. lbs. (120 Nm) and the exhaust pulley bolt to 50 ft. lbs. (68 Nm).
  11. Install the intake camshaft pulley blanking plug and tighten it to 27 ft. lbs. (37 Nm).
  12. Remove the Crankshaft TDC Timing Peg.
  13. Remove the Camshaft Alignment Plate from the camshafts.
  14. Turn the crankshaft two revolutions in the normal direction of rotation.
  15. Check the valve timing by reinstalling the Camshaft Alignment Plate and the Crankshaft TDC Timing Peg. If necessary loosen the timing pulleys and correct the camshaft alignment.
  16. Remove the Camshaft Alignment Plate and the Crankshaft TDC Timing Peg.
  17. Install the blanking plug.
  18. Install the valve cover and tighten the bolts as follows:
    1. Step 1: 18 inch lbs. (2 Nm)
    2. Step 2: 62 inch lbs. (7 Nm)
  19. Attach the PCV hose to the valve cover.
  20. Connect the VCT actuator electrical connector.
  21. Coat the spark plug thread with anti-seize grease, screw in the spark plugs and push in the spark plug connector until it engages.
  22. Connect the VCT valve electrical connector.
  23. Install the engine upper cover.
  24. Install the spark plug cover.
  25. Position the upper timing belt cover and the center timing belt cover.
  26. Install the engine front mount bracket. Tighten the bolts to 37 ft. lbs. (50 Nm).
  27. Attach the timing belt upper cover. Tighten the bolts to 88 inch lbs. (10 Nm)
  28. Install the engine front mount.
  29. Attach the power steering pump fluid reservoir.
  30. Attach the coolant expansion tank.
  31. Remove the hydraulic jack and wooden block.
  32. Raise and support the vehicle.
  33. Attach the lower timing belt cover. Tighten the bolts to 62 inch lbs. (7 Nm).
  34. Install the crankshaft pulley. Tighten the bolt to 85 ft. lbs. (115 Nm).
  35. Attach the multi-groove belt idler pulley. Tighten the bolt to 29 ft. lbs. (40 Nm).
  36. Attach the coolant pump pulley. Do not tighten the bolts at this stage.
  37. Install the accessory drive belt.
  38. Tighten the bolts on the coolant pump pulley to 17 ft. lbs. (24 Nm).
  39. Attach the drive belt cover.
  40. Lower the vehicle.
    NOTE
    When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
  41. Connect the battery negative cable.
  42. Install the battery cover.
  43. Check fluid levels and correct if necessary.
  44. Check the routing of vacuum hoses and cables and secure them with cable ties.

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You can keep this lint handy for any other car model,drive and timing belt in future.

Timing belt routing diagrams for cars and trucks?

Click the link below:---


Drive belt routing diagrams for cars and trucks?

Click this link below:---


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