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How to replace timing belt on Ford Focus 1.8 TDCi 2002-2005

Published June 29, 2015

Ford Focus 1.8 TDCi 2001, 2002-2005 cambelt change instructionts and replacement inteval. Full guide!

Replacement Interval Guide

  • Ford recommend:
  • Focus:
  • Replacement every 100,000 miles or 10 years.
  • Transit/Tourneo:
  • Replacement every 150,000 miles or 10 years.
  • The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head(s).

Repair Times – hrs

Remove & install 2,50

Special Tools

  • Flywheel locking tool – Ford No.303-393 (21-168).
  • Camshaft setting bar – Ford No.303-376 (21-162-B).
  • Crankshaft timing pin – Ford No.303-193 (21-104).
  • Camshaft sprocket puller – Ford No.303-651 (21-229).
  • Camshaft sprocket holding tool – Ford No.205-072 (15-030-A).

Special Precautions

  • Disconnect battery earth lead.
  • DO NOT turn crankshaft or camshaft when timing belt removed.
  • Remove glow plugs to ease turning engine.
  • Turn engine in normal direction of rotation (unless otherwise stated).
  • DO NOT turn engine via camshaft or other sprockets.
  • Observe all tightening torques.
How to replace timing belt on Ford Focus 1.8 TDCi 2002-2005
2001, 2002 ford focus belt diagram

Removal

NOTE: Vehicles built before 08/00 are fitted with manual tensioner which must be replaced with an automatic tensioner.

  1. Raise and support front of vehicle.
  2. Remove:
      • Intercooler cover.
      • Intercooler hoses.
  3. Disconnect intake air temperature (IAT) sensor multi-plug.
  4. Remove:
      • Intercooler.
      • Coolant expansion tank. DO NOT disconnect hoses.
      • PAS pipe bracket.
      • Cylinder head cover.
      • Auxiliary drive belt cover.
      • Auxiliary drive belt.
      • Alternator drive shaft.
      • Starter motor.
  5. Turn crankshaft clockwise until just before TDC on No.1 cylinder. Ensure camshaft parallel groove aligned with edge of cylinder head.
  6. Remove blanking plug from cylinder block. Insert timing pin [1] . Tool No.303-193 (21-104).
  7. Turn crankshaft clockwise until it stops against timing pin [1] .
  8. Fit flywheel locking tool [2] . Tool No.303-393 (21-168).NOTE: Crankshaft web MUST remain locked against timing pin.
  9. Fit setting bar to rear of camshaft [3] . Tool No.303-376 (21-162-B).
  10. Support engine.
  11. Remove:
      • RH engine mounting.
      • Engine mounting studs.
      • Timing belt cover [4] .
  12. Slacken tensioner bolt [5] .
  13. Turn tensioner pulley clockwise away from belt [6] . Use Allen key. Lightly tighten bolt [5] .
  14. Hold camshaft sprocket [7] . Tool No.205-072 (15-030-A).
  15. Slacken camshaft sprocket bolt [8] .
  16. Loosen camshaft sprocket from taper [9] . Tool No.303-651 (21-229).
  17. Ensure camshaft sprocket can turn freely without tilting.
  18. Remove timing belt.NOTE: DO NOT refit used belt.

    NOTE: If manual tensioner fitted it MUST be replaced with automatic tensioner.

Installation

NOTE: Refer to Ford dealer for revised tensioner. Ensure new timing belt has etched FORD logo denoting latest type.

NOTE: Ensure engine is cold before installing belt.

  1. Ensure crankshaft at TDC on No.1 cylinder.
  2. Ensure crankshaft web against timing pin [1] .
  3. Ensure flywheel locking tool located correctly [2] .
  4. Ensure camshaft locked with tool [3] .
  5. Ensure camshaft sprocket can turn freely without tilting.
  6. Ensure automatic tensioner at position shown [10] .
  7. Fit timing belt in anti-clockwise direction, starting at injection pump/high-pressure fuel pump sprocket. Ensure belt is taut between sprockets on non-tensioned side. Ensure directional arrows point in direction of rotation.
  8. Slacken tensioner bolt [5] .
  9. Turn tensioner pulley anti-clockwise until pointer at position shown [11] . Use Allen key.
  10. Tighten tensioner pulley bolt [5] . Tightening torque: 50 Nm.
  11. Hold camshaft sprocket [7] . Tool No.205-072 (15-030-A).
  12. Tighten camshaft sprocket bolt [8] . Tightening torque: 50 Nm.
  13. Remove tools [1] , [2] & [3] .NOTE: If necessary, mark crankshaft pulley with paint or chalk.
  14. Turn crankshaft almost 6 turns clockwise.
  15. Insert timing pin in cylinder block [1] .
  16. Turn crankshaft slowly clockwise to TDC on No.1 cylinder until crankshaft web against timing pin.
  17. Fit flywheel locking tool [2] .NOTE: Crankshaft web MUST remain locked against timing pin.
  18. Ensure tensioner pointer at position shown [11] . If not, repeat installation procedure.
  19. Ensure setting bar can be fitted to rear of camshaft [3] . If not, repeat installation procedure.
  20. Remove tools [1] , [2] & [3] .
  21. Fit blanking plug to cylinder block. Tightening torque: 24 Nm.
  22. If manual tensioner replaced with automatic tensioner, modify timing belt cover. File off inner corner [12] .
  23. Install components in reverse order of removal.
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