How to replace timing chain on Ford Focus 2.0 TDCi 2004-2011

Special tools

• Camshaft sprocket locking tool – Ford No.303-735.
• Flywheel timing pin – Ford No.303-1059.
• Flywheel locking tool – Ford No.303-393.
• Flywheel locking tool adaptor – Ford No.303-393-01.
• Tensioner locking tool – Ford No.100-010.

General precautions

• Disconnect battery earth lead.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• Observe tightening torques.
• If fitted: Mark position of crankshaft position (CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other sprockets.
• Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

• Removal/installation of timing chain requires:
  • Timing belt removal.
  • Camshaft housing removal.
• Ensure flywheel timing pin located correctly [1] .
• Ensure flywheel locking tool installed [2] .
• Ensure camshaft sprocket locking tool located correctly [3] .
• Align coloured chain links with timing mark on each sprocket [4] & [5] .
• Lock tensioner in retracted position:
  • Push plunger into tensioner housing [6] and insert tensioner locking tool [7] .
• Remove tensioner locking tool [7] to release timing chain tensioner plunger.