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Fusion2002.75(06/2002-)
ReportAnError
In-vehicle Repair
Special Tool(s) / General Equipment
UniversalFlangeHoldingWrench
205-072
Gauge,BoltAngle
303-174
AlignmentPlate,Camshaft
303-376B
Socket,SparkPlug
303-499
LockingTool,Crankshaft
303-748
LockingTool,TimingBeltTensioner
303-1054
Trolleyjack
Woodenblock
Materials
Name
Specification
ESD-M1C220-A
Removal
Allvehicles
1. Removethevalvecover.
Foradditionalinformation,referto:ValveCover(303-01Engine-1.25LDuratec-16V
(Sigma)/1.4LDuratec-16V(Sigma)/1.6LDuratec-16V(Sigma),In-vehicleRepair).
2. Loosenthecoolantpumppulleyretainingbolts.
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3. Removetheaccessorydrivebelt.
Foradditionalinformation,referto:AccessoryDriveBelt-1.25LDuratec-16V
(Sigma)/1.4LDuratec-16V(Sigma)/1.6LDuratec-16V(Sigma),VehiclesWith:Air
Conditioning(303-05AccessoryDrive,RemovalandInstallation).
4. Removethecrankshaftpulley.
5. Removethecoolantpumppulley.
6. Removethetimingbeltcoverretainingbolts.
1. Removethetimingbeltuppercoverretainingbolts.
2. Removethetimingbeltlowercoverretainingbolts.
Removethelowercover.
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7. Lowerthevehicle.
8. Detachthepowersteeringfluidreservoirfromthebracketandpositionittooneside.
9. Detachthecoolantexpansiontankfromthebracketandpositionittooneside.
10. Disconnectthegeneratorelectricalconnector.
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11. Detachthegeneratorfromtheengine.
1. Loosenthebolt.
2. Removethebolt.
3. Removethenutandthestud.
12.
NOTICE:Donotsupporttheenginedirectlyontheoilpan.
Placethetrolleyjackwithawoodenblockundertheengineandraiseitslightlyuntil
theenginefrontmountisfreefromstrain.
13. Removetheenginefrontmount.
Discardthenuts.
14. Removethetimingbeltuppercover.
15. Removetheenginefrontmountbracket.
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16. Usingthespecialtool,removethesparkplugs.
Engineswitheccentriccamtimingbelttensioner
17. Slackenthetimingbelttensionerandremovethetimingbelt.
Discardthetimingbelt.
18. Removethetimingbelttensioner.
Engineswithslottedbrackettimingbelttensioner
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19. Removethetimingbelttensionerandthetimingbelt.
Discardthetimingbelt.
Vehiclesbuilt09/2003onwards
20. Removethetimingbelt.
Detensionthetimingbeltandlockthetimingbelttensionerwiththespecialtool.
Discardthetimingbelt.
21. Removethetimingbelttensioner.
Vehiclesbuilt04/2005onwards
22. Removethetimingbelt.
Detensionthetimingbeltandlockthetimingbelttensionerwiththespecialtool.
Discardthetimingbelt.
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Installation
Allvehicles
1. Setthecrankshafttoapproximately20degreesbeforeTDC.
2. NOTE:Makesurethecamshaftpulleysturnonthecamshafts.
Loosenthecamshaftpulleyretainingbolts.
Discardtheretainingbolts.
3. TurnthecamshaftstoTDConcylindernumber1andinstallthespecialtool.
4. Removetheblankingplugandinstallthespecialtool.
Carefullyturnthecrankshaftagainstthespecialtool.
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5. NOTE:Installanewtimingbelt.
NOTE:Installthetimingbelt,beginningwiththecrankshafttimingpulleyworking
counterclockwise.
Installthetimingbelt.
6. Measuringthedepthofthethreadedholeinthecrankshaft.
Depthofthethreaded=42mm:UseanM12x29mmcrankshaftpulleycenterbolt.
Depthofthethreaded=52mm:UseanM12x44,5mmcrankshaftpulleycenterbolt.
Depthofthethreaded=81mm:UseanM14x80mmcrankshaftpulleycenterbolt.
7. Attachthetimingbeltlowercover.
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8. NOTE:Installanewcrankshaftpulleyretainingbolt.
Installthecrankshaftpulley.
Tightenthecrankshaftpulleyretainingbolt.
M12:Stage1:40Nm
M12:Stage2:90degrees
M14:Stage1:100Nm
M14:Stage2:90degrees
M14:Waitfor10seconds
M14:Stage3:15degrees
Engineswitheccentriccamtimingbelttensioner
9. Installthetimingbelttensioner.
10. Tensionthetimingbelt.
Tensionthetimingbeltbyturningthetensionercounterclockwiseuntilthearrow
pointsatthemarkandtightenthebolt.
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Engineswithslottedbrackettimingbelttensioner
11. Installthetimingbelttensionerandtensionthetimingbelt.
Screwintheboltsfingertight.
Tensionthetimingbeltbyturningthetensionerclockwiseuntilthearrowpointsinline
withthecenteroftherectangularholeandtightenthebolt.
Vehiclesbuilt09/2003onwards
12.
WARNING:Donotremovethespecialtool,untilthetimingbeltiscorrectly
positioned.Failuretofollowthisinstructionmayresultinpersonalinjury,ormay
damagethetimingbelttensioner.
Installthetimingbelttensioner.
13. Tensionthetimingbelt.
Removethespecialtool.
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Vehiclesbuilt04/2005onwards
14.
WARNING:Donotremovethespecialtool,untilthetimingbeltiscorrectly
positioned.Failuretofollowthisinstructionmayresultinpersonalinjury,ormay
damagethetimingbelttensioner.
Tensionthetimingbelt.
Removethespecialtool.
Allvehicles
15.
NOTICE:Donottightenthecamshaftpulleyboltsagainstthetimingplate.
NOTE:ThecamshaftsmustremainatTDC.
NOTE:Installnewcamshaftpulleyretainingbolts.
Usingthespecialtool,tightenthecamshaftpulleys.
16. Removespecialtool.
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17. Removethespecialtool.
18. NOTE:Onlyturntheengineinitsnormaldirectionofrotation.
Turntheenginetworevolutions.
19. Installthespecialtool.
Carefullyturnthecrankshaftagainstthespecialtool.
20. Checkthevalvetiming.
Ifnecessaryloosenthecamshaftpulleysandcorrectthecamshaftalignment.
Removethespecialtool.
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21. Removethespecialtool.
22. Installtheblankingplug.
23. Usingthespecialtool,installthesparkplugs.
Applygreasetothesparkplugthreads.
24. Installtheenginefrontmountbracket.
Tightentheboltsintheindicatedorderinthreestages.
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Stage1:Handtightenbolt1.
Stage2:Tightenbolts2to55Nm.
Stage3:Tightenbolt3to55Nm.
25. Installthetimingbeltuppercover.
26. NOTE:Installnewenginefrontmountretainingnuts.
Installtheenginefrontmount.
27. Removethetrolleyjack.
28. Attachthegenerator.
1. Installthestudandnut.
2. Installthebolt.
3. Tightenthebolt.
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29. Connectthegeneratorelectricalconnector.
30. Raiseandsupportthevehicle.
Foradditionalinformation,referto:Lifting(100-02JackingandLifting,Description
andOperation).
31. Installthetimingbeltuppercoverretainingbolts.
32. NOTE:Donottightenthecoolantpumppulleyretainingboltsatthisstage.
Installthecoolantpumppulley.
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33. Installtheaccessorydrivebelt.
Foradditionalinformation,referto:AccessoryDriveBelt-1.25LDuratec-16V
(Sigma)/1.4LDuratec-16V(Sigma)/1.6LDuratec-16V(Sigma),VehiclesWith:Air
Conditioning(303-05AccessoryDrive,RemovalandInstallation).
34. Tightenthecoolantpumppulleyretainingbolts.
35. Installthevalvecover.
Foradditionalinformation,referto:ValveCover(303-01Engine-1.25LDuratec-16V
(Sigma)/1.4LDuratec-16V(Sigma)/1.6LDuratec-16V(Sigma),In-vehicleRepair).
36. Attachthepowersteeringfluidreservoirtothebracket.
37. Attachthecoolantexpansiontanktothebracket.
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