Special tools
- Camshaft setting bar – Ford No.303-376 (21-162B).
- Crankshaft timing pin – Ford No.303-507 (21-210).
- Universal flange holding wrench – Ford No.205-072 (15-030-A).
- Universal flange holding wrench adapter 1 – Ford No.205-072-02 (15-030-A-02).
- Universal flange holding wrench adapter 2 – Ford No.205-072-01 (15-030-A-01).
General precautions
- Disconnect battery earth lead.
- Remove spark 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
- Engine at 45° BTDC No.1 cylinder [1] .
- Remove blanking plug from cylinder block [2] .
- Install crankshaft timing pin.
- Turn crankshaft slowly clockwise until it stops against timing pin.
- Lock camshafts with setting bar [3] .
- Lock timing chain tensioner in retracted position:
- Release ratchet [4] .
- Depress tensioner blade [5] .
- Insert tensioner locking pin [6] .
- Slacken bolt of each camshaft sprocket.
NOTE: Hold camshafts with spanner on hexagon.
- Remove camshaft sprockets and chain.
Installation
- Ensure crankshaft timing pin correctly fitted.
- Ensure camshaft setting bar correctly fitted [3] .
- Install camshaft sprockets and timing chain.
- Tighten bolt of each camshaft sprocket finger tight.
- Depress tensioner blade [5] .
- Remove tensioner locking pin [6] .
- Tighten bolt of each camshaft sprocket. Tightening torque: 72 Nm.
NOTE: Hold camshafts with spanner on hexagon.
- Remove crankshaft pulley centre bolt.
- Fit new friction washer [7] .
- Fit crankshaft pulley.
- Install M6 bolt in crankshaft pulley [8] .
- Fit new crankshaft pulley centre bolt.
- Tighten crankshaft pulley centre bolt. Tightening torque: 100 Nm + 90°.
- Remove:
- M6 bolt [8] .
- Camshaft setting bar [3] .
- Crankshaft timing pin.
- Turn crankshaft two turns clockwise until engine at 45° BTDC No.1 cylinder [1] .
- Install crankshaft timing pin.
- Turn crankshaft slowly clockwise until it stops against timing pin.
- Ensure M6 bolt can be fitted [8] . If not, repeat timing chain installation.
- Ensure camshaft setting bar can be fitted [3] . If not, repeat timing chain installation.