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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.

Replace timing belt on Ford C-MAX 2.0 TDCi 2007-2010

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.

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