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How to replace timing belt on Ford Fiesta 1.6 TDCi 2009-

Published July 31, 2015

Replacement Interval Guide

  • Ford recommend:
  • Fiesta/Fusion →2005:
  • Replacement every 150,000 miles or 10 years.
  • Fiesta/Fusion 2005→:
  • Replacement every 125,000 miles or 10 years.
  • Fiesta 2008→:
  • Tensioner pulley and guide pulley must be replaced.
  • 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.

Repair Times – hrs

Remove & install 1,70

Special Tools

  • Camshaft sprocket locking tool – Ford No.303-735 (21-263).
  • Crankshaft/high-pressure fuel pump aligning tool – Ford No.303-732 (21-260).
  • Flywheel locking tool – Ford No.303-734 (21-262).

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 Fiesta 1.6 TDCi 2009-
How to replace timing belt on Ford Fiesta 1.6 TDCi 2009-

Removal

  1. Drain coolant.
  2. Raise and support front of vehicle.
  3. Disconnect hose from coolant expansion tank.
  4. Remove screws retaining coolant expansion tank. Move expansion tank to one side.
  5. Disconnect:
      • Fuel temperature sensor multi-plug.
      • Wiring harness from timing belt upper cover.
  6. Remove:
      • Timing belt upper cover [1] .
      • Auxiliary drive belt cover.
      • Auxiliary drive belt.
  7. Fit flywheel locking tool [2] . Tool No.303-734 (21-262).
  8. Remove:
      • Crankshaft pulley bolt [3] .
      • Crankshaft pulley [4] .
      • Flywheel locking tool [2] .
  9. Disconnect wiring harness from timing belt lower cover.
  10. Remove timing belt lower cover [5] .
  11. Fit crankshaft pulley bolt [3] .
  12. Turn crankshaft slowly clockwise until camshaft sprocket timing hole at 2 o’clock position [6] .
  13. Fit camshaft sprocket locking tool [7] . Tool No.303-735 (21-263).
  14. Insert crankshaft aligning tool [8] . Tool No.303-732 (21-260).
  15. Slacken tensioner pulley bolt [9] .
  16. Remove:
      • Tensioner pulley bolt [9] .
      • Tensioner pulley.
      • Fiesta 2008→: Guide pulley nut [10] .
      • Fiesta 2008→: Guide pulley.
      • Crankshaft pulley bolt [3] .
      • Crankshaft aligning tool [8] .
      • Timing belt guide [11] .
      • Reluctor [12] .

    NOTE: Ensure reluctor is not damaged.

  17. Support engine.
  18. Remove:
      • PAS reservoir. DO NOT disconnect hoses.
      • Camshaft sprocket locking tool [7] .
      • RH engine mounting and bracket.
      • Timing belt.

Installation

NOTE: DO NOT refit used belt. Engine must be COLD when installing belt.

  1. Except Fiesta 2008→:
      • Fit tensioner pulley.
      • Fit tensioner pulley bolt [9] . Tighten bolt finger tight.
  2. Fiesta 2008→:
      • Fit new tensioner pulley.
      • Fit tensioner pulley bolt [9] . Tighten bolt finger tight.
      • Fit new guide pulley.
      • Fit guide pulley nut [10] . Tightening torque: 20 Nm.
  3. Fit timing belt loosely to sprockets and pulleys.NOTE: Ensure arrow on belt faces direction of rotation.
  4. Fit RH engine mounting and bracket.NOTE: Engine mounting nuts must always be renewed.
  5. Fit PAS reservoir.
  6. Insert high-pressure fuel pump aligning tool [13] . Tool No.303-732 (21-260).NOTE: If there is no hole in rear bracket, ensure holes in sprocket and cylinder block aligned [14] .
  7. Remove high-pressure fuel pump aligning tool [13] .
  8. Fit camshaft sprocket locking tool [7] .NOTE: Ensure crankshaft sprocket Woodruff key at 11 o’clock position.
  9. Install:
      • Reluctor [12] .
      • Crankshaft sprocket bolt [3] . Tighten bolt finger tight.
  10. Insert crankshaft aligning tool [8] .
  11. Fit timing belt.
  12. Turn tensioner pulley anti-clockwise until pointer aligned in window [15] . Use Allen key.
  13. Tighten tensioner pulley bolt [9] . Tightening torque: 30 Nm.
  14. Remove:
      • Crankshaft aligning tool [8] .
      • Camshaft sprocket locking tool [7] .
  15. Fit timing belt guide [11] .
  16. Turn crankshaft slowly ten turns clockwise.
  17. Insert crankshaft aligning tool [8] .
  18. Ensure camshaft sprocket locking tool can be inserted [7] .
  19. If locking tool cannot be inserted: Repeat installation procedure.
  20. Remove crankshaft aligning tool [8] .
  21. Ensure high-pressure fuel pump aligning tool can be inserted [13] .NOTE: If there is no hole in rear bracket, ensure holes in sprocket and cylinder block aligned [14] .
  22. If not: Repeat installation procedure.
  23. Remove:
      • Camshaft sprocket locking tool [7] .
      • High-pressure fuel pump aligning tool [13] .
      • Crankshaft pulley bolt [3] .
  24. Fit:
      • Timing belt lower cover [5] .
      • Flywheel locking tool [2] .
      • Crankshaft pulley [4] .
      • Crankshaft pulley bolt [3] . Use new bolt. Tightening torque: 30 Nm + 180°.
  25. Remove flywheel locking tool [2] .
  26. Install components in reverse order of removal.
  27. Refill and bleed cooling system.
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Published in Fiesta