How to replace timing belt on Ford C-MAX 2.0 TDCi 2007-2010

Replacement Interval Guide

• Ford recommend:
• →2005:
• Replacement every 150,000 miles or 10 years (tensioner pulley & guide pulley must also be replaced).
• 2005→:
• Replacement every 125,000 miles or 10 years (tensioner pulley & guide pulley must also 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:
Focus	2,30
Focus C-MAX/C-MAX	2,40

Special Tools

• Camshaft sprocket locking tool – Ford No.303-735.
• Flywheel timing pin – Ford No.303-1059.
• Flywheel locking tool – Ford No.303-393.
• Flywheel locking tool adaptor – Ford No.303-393-01.

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. Raise and support front of vehicle.
2. Remove:
   • Brake fluid reservoir from plenum chamber cover (if necessary). DO NOT disconnect hoses.
   • Windscreen wiper arms.
   • Plenum chamber cover.
   • Engine top cover.
   • Coolant expansion tank. DO NOT disconnect hoses.
   • Engine undershield.
   • Auxiliary drive belt.
   • Starter motor.
3. Support engine.
4. Remove:
   • RH engine mounting.
   • Timing belt upper cover [1] .
5. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure camshaft sprocket timing hole at 4 o’clock position [2] .NOTE: No.1 cylinder nearest to flywheel.
6. Fit:
   • Camshaft sprocket locking tool [3] . Tool No.303-735.
   • Flywheel timing pin [4] . Tool No.303-1059.
   • Flywheel locking tool [5] . Tool Nos.303-393/01.
7. Remove:
   • Crankshaft pulley bolt [6] .
   • Crankshaft pulley [7] .
8. Disconnect crankshaft position (CKP) sensor multi-plug.
9. Remove:
   • Crankshaft position (CKP) sensor.
   • Timing belt lower cover [8] .
   • Reluctor [9] .NOTE: Ensure reluctor is not damaged.
   • Tensioner pulley bolt [10] .
   • Tensioner pulley.
   • RH engine mounting bracket.
   • Guide pulley.
   • Timing belt.

Installation

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

1. Ensure flywheel timing pin located correctly [4] .
2. Ensure flywheel locked with tool [5] .
3. Ensure camshaft sprocket locking tool located correctly [3] .
4. Fit:
   • New guide pulley.
   • RH engine mounting bracket. Tightening torque: 56 Nm.
   • Timing belt.

   NOTE: Ensure arrow on belt faces direction of rotation.

5. Fit new tensioner pulley. Finger tighten bolt [10] .
6. Ensure belt is taut between sprockets.
7. Turn tensioner pulley anti-clockwise until pointer in position as shown [11] . Use Allen key [12] .NOTE: Tensioner pointer to left of notch in baseplate [13] .
8. Tighten tensioner pulley bolt [10] . Tightening torque: 21 Nm.
9. Install:
   • Reluctor [9] .NOTE: Ensure reluctor is not damaged.
   • Crankshaft pulley [7] .
   • Crankshaft pulley bolt [6] . Use old bolt.
10. Tighten crankshaft pulley bolt [6] . Tightening torque: 50 Nm.
11. Remove:
    • Flywheel timing pin [4] .
    • Camshaft sprocket locking tool [3] .
    • Flywheel locking tool [5] .
12. Turn crankshaft slowly four turns clockwise.
13. Ensure camshaft sprocket timing hole at 4 o’clock position [2] .
14. Fit:
    • Flywheel timing pin [4] .
    • Flywheel locking tool [5] .
15. Ensure camshaft sprocket locking tool can be inserted [3] .
16. If locking tool cannot be inserted: Repeat installation procedure.
17. Remove:
    • Crankshaft pulley bolt [6] .
    • Crankshaft pulley [7] .
    • Reluctor [9] .

    NOTE: Ensure reluctor is not damaged.

18. Hold tensioner pulley. Use Allen key [12] .
19. Slacken tensioner pulley bolt [10] .
20. Turn tensioner pulley until pointer aligned with notch [14] & [15] .
21. Tighten tensioner pulley bolt [10] . Tightening torque: 21 Nm.
22. Install:
    • Reluctor [9] .NOTE: Ensure reluctor is not damaged.
    • Timing belt lower cover [8] .
    • Crankshaft pulley [7] .
    • Crankshaft pulley bolt [6] .
23. Tighten crankshaft pulley bolt [6] . Use new bolt. Tightening torque: 70 Nm + 62°.
24. Remove:
    • Flywheel timing pin [4] .
    • Camshaft sprocket locking tool [3] .
    • Flywheel locking tool [5] .
25. Install components in reverse order of removal.NOTE: If battery has been disconnected, re-initialization of window motors may be required.