How to replace timing belt on Ford C-MAX 1.6 TDCi 2007-2010

Replacement Interval Guide

• Ford recommend:
• →2005:
• Replacement every 150,000 miles or 10 years.
• 2005→:
• 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.

Repair Times – hrs

Remove & install:
Focus	1,50
Focus C-MAX/C-MAX	1,70

Special Tools

• Auxiliary drive belt tensioner tool – Ford No.303-676 (21-235).
• Camshaft sprocket locking tool – Ford No.303-735.
• Crankshaft/fuel pump aligning tool – Ford No.303-732.
• Flywheel locking tool – Ford No.303-734.
• 5 mm drill bit.

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.

Removal

1. Drain cooling system.
2. Raise and support front of vehicle.
3. Remove:
   • Brake fluid reservoir from plenum chamber cover. DO NOT disconnect hoses.
   • Windscreen wiper arms.
   • Plenum chamber cover.
   • Auxiliary drive belt cover.
   • Auxiliary drive belt. Use tool No.303-676 (21-235) & 5 mm drill bit.
4. Disconnect top hose from coolant expansion tank.
5. Remove screws retaining coolant expansion tank. Move expansion tank to one side.
6. Support engine.
7. Remove:
   • RH engine mounting [1] .
   • Timing belt upper cover [2] .
   • RH engine mounting bracket bolts [3] .
   • RH engine mounting bracket [4] .
8. Fit flywheel locking tool [5] . Tool No.303-734.
9. Remove:
   • Crankshaft pulley bolt [6] .
   • Crankshaft pulley [7] .
   • Flywheel locking tool [5] .
   • Timing belt lower cover [8] .
10. Fit crankshaft pulley bolt [6] .
11. Turn crankshaft slowly clockwise until camshaft sprocket timing hole at 10 o’clock position [9] .
12. Fit camshaft sprocket locking tool [9] . Tool No.303-735.
13. Insert crankshaft aligning tool [10] . Tool No.303-732.
14. Slacken tensioner pulley bolt [11] .
15. Remove:
    • Crankshaft pulley bolt [6] .
    • Crankshaft aligning tool [10] .
    • Timing belt guide [12] .
    • Reluctor [13] .NOTE: Ensure reluctor is not damaged.
    • Timing belt.

Installation

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

1. Ensure crankshaft sprocket Woodruff key at 11 o’clock position.
2. Ensure camshaft sprocket locking tool located correctly [9] .
3. Insert fuel pump aligning tool [14] . Tool No.303-732.
4. Fit timing belt loosely to sprockets and pulleys.
5. Install:
   • Reluctor [13] .
   • Crankshaft sprocket bolt [6] . Tighten bolt finger tight.
6. Remove fuel pump aligning tool [14] .
7. Insert crankshaft aligning tool [10] .
8. Fit timing belt.NOTE: Ensure arrow on belt faces direction of rotation.
9. Turn tensioner pulley anti-clockwise until pointer aligned in window [15] . Use Allen key.
10. Tighten tensioner bolt to 23 Nm [11] .
11. Remove:
    • Crankshaft aligning tool [10] .
    • Camshaft sprocket locking tool [9] .
12. Fit timing belt guide [12] .
13. Turn crankshaft slowly ten turns clockwise.
14. Insert crankshaft aligning tool [10] .
15. Ensure camshaft sprocket locking tool can be inserted [9] .
16. If locking tool cannot be inserted: Repeat installation procedure.
17. Remove:
    • Crankshaft aligning tool [10] .
    • Camshaft sprocket locking tool [9] .
    • Crankshaft pulley bolt [6] .
18. Fit:
    • Timing belt lower cover [8] .
    • Flywheel locking tool [5] .
    • Crankshaft pulley [7] .
    • Crankshaft pulley bolt [6] . Use new bolt. Tightening torque: 30 Nm + 180°.
19. Remove flywheel locking tool [5] .
20. Install components in reverse order of removal.
21. Tighten RH engine mounting bracket bolts [3] . Tightening torque: 55 Nm.
22. Tighten RH engine mounting bolts [16] . Tightening torque: 90 Nm.
23. Tighten RH engine mounting nuts [17] . Use new nuts. Tightening torque: 80 Nm.
24. Refill and bleed cooling system.NOTE: If battery has been disconnected, re-initialization of window motors may be required.