How to replace timing belt on Ford Mondeo 1.6 TDCi 2011-2012

Replacement Interval Guide

• Ford recommend replacement every 125,000 miles or 10 years (tensioner pulley and guide pulley must also be replaced).

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	2,10
Mondeo	2,00
C-MAX/Grand C-MAX	1,80

Special Tools

• Camshaft sprocket locking tool – No.303-735.
• Crankshaft aligning tool – No.303-732.
• Flywheel locking tool – 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.

Removal

1. Raise and support front of vehicle.
2. Remove coolant expansion tank. Move to one side.
3. Remove:
   • Engine top cover.
   • Timing belt upper cover [1] .
   • RH front wheel.
   • RH splash guard.
   • Engine undershield (if fitted).
   • Auxiliary drive belt.
4. Disconnect crankshaft position (CKP) sensor.
5. Move aside engine wiring harness (on timing belt cover).
6. Remove starter motor.
7. Fit flywheel locking tool [2] . Tool No.303-393.
8. Remove:
   • Crankshaft pulley bolt [3] .
   • Crankshaft pulley [4] .
   • Timing belt lower cover [5] .
   • Crankshaft position (CKP) sensor.
   • Timing belt guide [6] .
   • Flywheel locking tool [2] .
9. Support engine.
10. Remove:
    • RH engine mounting.
    • RH engine mounting bracket.
11. Fit crankshaft pulley bolt [3] . Tightening torque: 20 Nm.
12. Turn crankshaft slowly clockwise until camshaft sprocket timing hole at 2 o’clock position [7] .
13. Install:
    • Camshaft sprocket locking tool [8] . Tool No.303-735.
    • Crankshaft aligning tool [9] . Tool No.303-732.
    • NOTE: Ensure crankshaft position (CKP) sensor reluctor is not damaged.
14. Slacken tensioner pulley bolt [10] .
15. Remove:
    • Crankshaft pulley bolt [3] .
    • Crankshaft aligning tool [9] .
    • Reluctor [11] .
    • Timing belt.
    • Tensioner pulley.
    • Guide pulley nut [12] .
    • Guide pulley.

Installation

1. Fit new guide pulley. Tighten nut [12] . Tightening torque: 37 Nm.
2. Fit new tensioner pulley. Finger tighten bolt [10] .
3. Insert suitable locking tool (6 mm) in high-pressure fuel pump [13] .
4. Ensure camshaft sprocket locking tool located correctly [8] .
5. Fit timing belt loosely to sprockets, guide pulley and tensioner pulley.
6. Install:
   • Reluctor [11] .
   • Crankshaft pulley bolt [3] . Tighten bolt finger tight.
   • Crankshaft aligning tool [9] .
7. Turn tensioner pulley anti-clockwise until pointer aligned in window [14] . Use Allen key.
8. Tighten tensioner pulley bolt [10] . Tightening torque: 30 Nm.
9. Remove:
   • Crankshaft aligning tool [9] .
   • Camshaft sprocket locking tool [8] .
   • High-pressure fuel pump locking tool [13] .
10. Fit timing belt guide [6] .
11. Turn crankshaft slowly 10 turns clockwise.
12. Ensure camshaft sprocket timing hole at 2 o’clock position [7] .
13. Fit:
    • Crankshaft aligning tool [9] .
    • Camshaft sprocket locking tool [8] .
    • High-pressure fuel pump locking tool [13] .
14. If tools cannot be inserted: Repeat installation procedure.
15. Remove:
    • Crankshaft aligning tool [9] .
    • Camshaft sprocket locking tool [8] .
    • High-pressure fuel pump locking tool [13] .
    • Crankshaft pulley bolt [3] .
16. Fit:
    • Timing belt lower cover [5] .
    • Crankshaft pulley [4] .
    • Crankshaft pulley bolt [3] . Use new bolt. Tightening torque: 35 Nm + 190°.
17. Install components in reverse order of removal.