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How to replace timing belt on Ford Focus 1.6i 1998-2005

Replacement Interval Guide

  • Ford recommend replacement every 100,000 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
PAS & AC +0,30

Special Tools

  • Camshaft setting bar – Ford No.303-376 (21-162B).
  • Crankshaft timing pin – Ford No.303-748.
  • Holding tool – Ford No.205-072 (15-030A).
  • 09/2003→: Tensioner pulley locking pin – Ford No.303-1054.

Special Precautions

  • Disconnect battery earth lead.
  • DO NOT turn crankshaft or camshaft when timing belt removed.
  • Remove spark 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 Focus 1.6i 1998-2005

Removal

WARNING: Crankshaft sprocket NOT keyed to crankshaft.

  1. Raise and support front of vehicle.
  2. Remove:
      • RH front wheel.
      • Auxiliary drive belt cover.
      • Auxiliary drive belt(s).
      • Auxiliary drive belt guide pulley (if fitted) [1] .
      • Water pump pulley [2] .
      • Cylinder head cover.
      • Coolant expansion tank. DO NOT disconnect hoses.
      • PAS reservoir. DO NOT disconnect hoses.
      • Alternator.
      • Blanking plug from cylinder block [3] .
  3. Turn crankshaft clockwise until just before TDC on No.1 cylinder.
  4. Insert crankshaft timing pin. Tool No.303-748.
  5. Turn crankshaft slowly clockwise until it stops against timing pin.
  6. Ensure setting bar can be fitted [4] . Tool No.303-376 (21-162B).
  7. If setting bar cannot be fitted:
      • Remove timing pin. Turn crankshaft one turn clockwise.
      • Insert timing pin. Ensure crankshaft web against timing pin.
      • Ensure setting bar can be fitted.
  8. Remove:
      • Crankshaft pulley bolt [5] .
      • Crankshaft pulley [6] .
      • Timing belt lower cover [7] .
  9. Support engine.
  10. Remove:
      • RH engine mounting.
      • Timing belt upper cover [8] .
      • RH engine mounting bracket [9] .

    NOTE: There are three types of tensioner.

  11. Tensioner – type A:
      • Slacken tensioner bolts [10] .
      • Turn tensioner anti-clockwise to release tension on belt [11] . Use Allen key (8 mm).
  12. Tensioner – type B:
      • Slacken tensioner pulley bolt [12] .
      • Turn tensioner cam clockwise to release tension on belt [13] . Use Allen key (6 mm).
  13. Tensioner – type C – 09/2003→:
      • Pull on belt to depress tensioner pulley and insert locking pin [14] . Tool No.303-1054.
      • Remove tensioner bolts [15] .
      • Remove tensioner pulley.
  14. All models:
      • Remove timing belt.

Installation

WARNING: Crankshaft sprocket NOT keyed to crankshaft.

  1. Ensure setting bar fitted correctly [4] .
  2. Ensure crankshaft at TDC on No.1 cylinder.
  3. Ensure crankshaft timing pin located correctly.
  4. Remove setting bar [4] .
  5. Hold camshaft sprockets [16] . Use tool No.205-072 (15-030A).
  6. Slacken bolt of each camshaft sprocket [17] .

    NOTE: DO NOT use setting bar to hold camshafts when slackening bolts.

  7. Tap each camshaft sprocket gently to loosen it from taper.
  8. Ensure camshaft sprockets can turn freely without tilting.
  9. Fit setting bar to rear of camshafts [4] .
  10. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket.

    NOTE: There are three types of tensioner.

  11. Tensioner – type A:
      • Turn tensioner clockwise until indicator central with rectangular recess [18] . Use Allen key (8 mm).
      • Tighten tensioner bolts [10] . Tightening torque: 20 Nm.
  12. Tensioner – type B:
      • Turn tensioner cam anti-clockwise until arrow in centre of window [19] . Use Allen key (6 mm).
      • Tighten tensioner pulley bolt [12] . Tightening torque: 20 Nm.
  13. Tensioner – type C – 09/2003→:
      • Fit tensioner pulley.
      • Tighten tensioner bolts [15] . Tightening torque: 20 Nm.
  14. All models:
      • Ensure belt is taut between sprockets.
      • Install:
      • Timing belt lower cover [7] .
      • Crankshaft pulley [6] .
  15. Tighten crankshaft pulley bolt [5] . Tightening torque: 40 Nm + 90°. Use new bolt.
  16. Tensioner – type C – 09/2003→: Remove tensioner pulley locking pin [14] .
  17. Hold camshaft sprockets [16] . Use tool No.205-072 (15-030A).
  18. Tighten bolt of each camshaft sprocket [17] . Use new bolts. Tightening torque: 60 Nm.

    NOTE: DO NOT use setting bar to hold camshafts when tightening bolts.

  19. Remove:
      • Timing pin.
      • Setting bar [4] .
  20. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
  21. Insert crankshaft timing pin.
  22. Turn crankshaft slowly clockwise until it stops against timing pin.
  23. Ensure setting bar can be fitted [4] .
  24. If not:
      • Hold camshaft sprockets [16] . Use tool No.205-072 (15-030A).
      • Slacken bolt of each camshaft sprocket [17] .
      • Slowly turn camshafts with spanner on hexagon [20] .
      • Fit setting bar to rear of camshafts [4] .
      • Hold camshaft sprockets [16] . Use tool No.205-072 (15-030A).
      • Tighten bolt of each camshaft sprocket [17] . Tightening torque: 60 Nm.

    NOTE: DO NOT use setting bar to hold camshafts when tightening bolts.

  25. Remove:
      • Timing pin.
      • Setting bar [4] .
  26. Fit blanking plug and tighten to 20 Nm [3] .
  27. Install components in reverse order of removal.
  28. Tighten RH engine mounting bracket bolts [21] . Tightening torque: 55 Nm.
  29. Tighten RH engine mounting nuts and bolts. Tightening torque: 48 Nm.

    NOTE: Engines without auxiliary drive belt tensioner must have new belt fitted using special tools.

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