How to Replace timing chain on Ford C-Max 1.6 2005

Ford C-Max 1.6 2005 cambelt change instructions and replacement inteval. Full guide!

Special tools

• Camshaft setting bar – Ford No.303-376B.
• Crankshaft timing pin – Ford No.303-748.
• Holding tool – Ford No.205-072.
• Tensioner pulley locking pin – Ford No.303-1054.

Special precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove spark 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.

Valve timing procedures

Removal

WARNING: Crankshaft sprocket NOT keyed to crankshaft.

1. Raise and support front of vehicle.
2. Remove:
   • RH front wheel.
   • RH wheel arch liner.
   • Water pump pulley [1] .
   • Auxiliary drive belt(s).
     NOTE: Auxiliary drive belt(s) require cutting and cannot be reused.
   • Alternator.
3. Disconnect:
   • Crankcase ventilation hose.
   • Camshaft position (CMP) sensor multi-plug.
   • Spark plug leads.
4. Remove:
   • Cylinder head cover.
   • PAS reservoir. DO NOT disconnect hoses.
5. Disconnect power steering pressure (PSP) switch multi-plug.
6. Remove:
   • Coolant expansion tank. DO NOT disconnect hoses.
   • Blanking plug from cylinder block [2] .
7. Turn crankshaft clockwise until just before TDC on No.1 cylinder.
8. Fit crankshaft timing pin [3] . Tool No.303-748.
9. Turn crankshaft slowly clockwise until it stops against timing pin.
10. Ensure camshaft setting bar can be fitted [4] . Tool No.303-376B.
11. If setting bar cannot be fitted:
    • Remove crankshaft timing pin [3] .
    • Turn crankshaft one turn clockwise.
    • Fit crankshaft timing pin [3] . Ensure crankshaft web against timing pin.
    • Ensure camshaft setting bar can be fitted [4] .
12. Support engine.
13. Remove:
    • RH engine mounting.
    • RH engine mounting bracket.
    • Timing belt upper cover [5] .
14. Remove:
    • Crankshaft pulley bolt [6] .
    • Crankshaft pulley [7] .
    • Timing belt lower cover [8] .
15. Push on belt to depress tensioner pulley and insert locking pin [9] . Tool No.303-1054.
16. Remove timing belt.

Installation

WARNING: Crankshaft sprocket NOT keyed to crankshaft.

1. Ensure crankshaft timing pin located correctly [3] .
2. Ensure camshaft setting bar fitted correctly [4] .
3. Hold camshaft sprockets [10] . Use tool No.205-072.
   NOTE: Use sleeves on holding tool studs to protect camshaft sprockets from damage (part No.E890438S).
4. Remove bolt of each camshaft sprocket [11] .
5. Fit new bolt to each camshaft sprocket [11] . Tighten bolts finger tight.
6. Ensure camshaft sprockets can turn freely without tilting.
7. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket.
8. Ensure belt is taut between sprockets.
9. Remove tensioner pulley locking pin [9] .
10. Hold camshaft sprockets [10] .
    NOTE: Use sleeves on holding tool studs to protect camshaft sprockets from damage (part No.E890438S).
11. Tighten bolt of each camshaft sprocket [11] . Tightening torque: 60 Nm.
    NOTE: DO NOT use setting bar to hold camshafts when tightening bolts.
12. Fit timing belt lower cover [8] .
13. Check depth of crankshaft threaded hole [12] . Use suitable measuring tool [13] .
    • 42 mm: Use new crankshaft pulley bolt (M12 x 29 mm).
    • 52 mm: Use new crankshaft pulley bolt (M12 x 44,5 mm).
    • 81 mm: Use new crankshaft pulley bolt (M14 x 80 mm).
14. Fit crankshaft pulley [7] .
15. Tighten crankshaft pulley bolt [6] . Use new bolt. Tightening torque:
    • M12: 40 Nm + 90°.
    • M14: 100 Nm + 90°. Wait 10 seconds. Tighten crankshaft pulley bolt a further 15°.
16. Remove:
    • Crankshaft timing pin [3] .
    • Camshaft setting bar [4] .
17. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
18. Fit crankshaft timing pin [3] .
19. Turn crankshaft slowly clockwise until it stops against timing pin.
20. Ensure camshaft setting bar can be fitted [4] .
21. If not: Repeat tensioning procedure.
22. Remove:
    • Crankshaft timing pin [3] .
    • Camshaft setting bar [4] .
23. Fit blanking plug to cylinder block [2] . Tightening torque: 20 Nm.
24. Install components in reverse order of removal.
    NOTE: If battery has been disconnected, re-initialization of window motors may be required.