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How to replace timing belt on Ford C-MAX 1.8 TDCi 2007-2010

Published June 26, 2015

Replacement Interval Guide

  • Ford recommend replacement every 125,000 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 2,40

Special Tools

  • Camshaft setting bar – Ford No.303-376.
  • Camshaft sprocket puller – Ford No.303-651.
  • Camshaft sprocket holding tool – Ford No.205-072.
  • Crankshaft timing pin – Ford No.303-193.
  • Flywheel locking tool – Ford No.303-393.

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.

Replace timing belt Ford C-MAX 1,8 TDCi 2007-2010

Removal

  1. Raise and support front of vehicle.
  2. Remove engine top cover.
  3. Disconnect:
      • Manifold absolute pressure (MAP) sensor.
      • Crankcase ventilation hoses from cylinder head cover.
      • Camshaft position (CMP) sensor.
  4. Remove cylinder head cover.
  5. Disconnect crankcase ventilation hoses from oil separator.
  6. Remove:
      • Oil separator.
      • Coolant expansion tank. DO NOT disconnect hoses.
      • Intercooler outlet hose.
      • Fuel filter cover.
  7. Disconnect:
      • Fuel pipes from fuel filter.
      • Cylinder head temperature (CHT) sensor.
  8. Remove:
      • Engine lifting bracket.
      • Fuel filter and bracket.
      • Engine undershield.
      • Auxiliary drive belt.
  9. With AC – remove alternator drive shaft.
  10. Remove starter motor.
  11. Turn crankshaft clockwise until just before TDC on No.1 cylinder. Ensure groove in camshaft in position as shown [1] .
  12. Remove blanking plug from cylinder block. Insert timing pin [2] . Tool No.303-193.
  13. Turn crankshaft clockwise until it stops against timing pin [2] .
  14. Fit flywheel locking tool [3] . Tool No.303-393.NOTE: Crankshaft web MUST remain locked against timing pin.
  15. Fit setting bar to rear of camshaft [4] . Tool No.303-376.
  16. Support engine.
  17. Remove:
      • RH engine mounting.
      • Engine mounting bracket studs.
      • Timing belt cover [5] .
  18. Slacken tensioner pulley bolt [6] .
  19. Remove tensioner pulley.
  20. Hold camshaft sprocket [7] . Use tool No.205-072.
  21. Slacken camshaft sprocket bolt [8] .
  22. Loosen camshaft sprocket from taper [9] . Use tool No.303-651.
  23. Ensure camshaft sprocket can turn freely without tilting.
  24. Remove timing belt.NOTE: DO NOT refit used belt.

Installation

NOTE: Engine must be COLD when installing belt.

  1. Check tensioner pulley for smooth operation. Replace if necessary.
  2. Ensure crankshaft at TDC on No.1 cylinder.
  3. Ensure crankshaft web against timing pin [2] .
  4. Ensure flywheel locking tool located correctly [3] .
  5. Ensure camshaft locked with tool [4] .
  6. Ensure camshaft sprocket can turn freely without tilting.
  7. Fit tensioner pulley.
  8. Ensure tensioner pulley at position shown [10] . Lightly tighten bolt [6] .
  9. Fit timing belt. Ensure belt is taut between sprockets on non-tensioned side.NOTE: Ensure arrow on belt faces direction of rotation.
  10. Turn tensioner pulley anti-clockwise until pointer at position shown [11] . Use Allen key.
  11. Tighten tensioner pulley bolt [6] . Tightening torque: 50 Nm.
  12. Hold camshaft sprocket [7] .
  13. Tighten camshaft sprocket bolt [8] . Tightening torque: 50 Nm.
  14. Remove tools [2] , [3] & [4] .
  15. Turn crankshaft almost six turns clockwise.
  16. Insert timing pin in cylinder block [2] .
  17. Turn crankshaft slowly clockwise to TDC on No.1 cylinder until crankshaft web against timing pin [2] .
  18. Fit flywheel locking tool [3] .NOTE: Crankshaft web MUST remain locked against timing pin.
  19. Ensure tensioner pointer at position shown [11] . If not: Repeat installation procedure.
  20. Ensure setting bar can be fitted to rear of camshaft [4] . If not: Repeat installation procedure.
  21. Remove tools [2] , [3] & [4] .
  22. Fit blanking plug to cylinder block.
  23. Install components in reverse order of removal.NOTE: If battery has been disconnected, re-initialization of window motors may be required.
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Published in C-MAX