How to replace timing belt on Ford Mondeo 1.8 TDCi 2007-2010

Replacement Interval Guide

• Ford recommend 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(s).

Repair Times – hrs

Remove & install:
Mondeo	2,90
S-MAX/Galaxy	3,40

Special Tools

• Camshaft setting bar – Ford No.303-376B.
• Camshaft sprocket puller – Ford No.303-651.
• Camshaft sprocket holding tool – Ford No.205-072.
• Crankshaft timing pin – Ford No.303-193.
• Flywheel locking tool – Ford 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:
   • Engine top cover.
   • Air filter assembly.
   • Crankcase ventilation hoses from cylinder head cover.
   • Cylinder head cover.
3. Disconnect crankcase ventilation hoses from oil separator.
4. Remove:
   • Oil separator.
   • Fuel filter cover (if fitted).
5. Disconnect:
   • Fuel pipes from fuel filter.
   • Cylinder head temperature (CHT) sensor (if necessary).
6. Remove:
   • Engine lifting bracket.
   • Fuel filter and bracket.
   • Engine undershield.
   • RH front wheel.
   • RH wheel arch liner.
   • Engine torque reaction link.
   • Auxiliary drive belt.
   • Alternator drive shaft.
7. Move AC compressor to one side. DO NOT disconnect hoses.
8. Remove starter motor.
9. Turn crankshaft clockwise until just before TDC on No.1 cylinder. Ensure groove in camshaft in position as shown [1] .
10. Remove blanking plug from cylinder block. Insert timing pin [2] . Tool No.303-193.
11. Turn crankshaft clockwise until it stops against timing pin [2] .
12. Fit flywheel locking tool [3] . Tool No.303-393.

    NOTE: Crankshaft web MUST remain locked against timing pin.

13. Fit setting bar to rear of camshaft [4] . Tool No.303-376B.
14. Support engine.
15. Remove:
    • Intercooler outlet hose.
    • RH engine mounting.
    • Timing belt cover [5] .
16. Slacken tensioner pulley bolt [6] .
17. Turn tensioner pulley clockwise away from belt [7] . Use Allen key. Lightly tighten bolt [6] .
18. Hold camshaft sprocket [8] . Tool No.205-072.
19. Slacken camshaft sprocket bolt [9] .
20. Loosen camshaft sprocket from taper [10] . Tool No.303-651.
21. Ensure camshaft sprocket can turn freely without tilting.
22. Remove timing belt.

    NOTE: DO NOT refit used belt.

Installation

NOTE: Engine must be COLD when installing belt.

1. Ensure crankshaft at TDC on No.1 cylinder.
2. Ensure crankshaft web against timing pin [2] .
3. Ensure flywheel locking tool located correctly [3] .
4. Ensure camshaft locked with tool [4] .
5. Ensure camshaft sprocket can turn freely without tilting.
6. Ensure tensioner pulley pointer can be turned freely clockwise.
7. Ensure tensioner pulley at position shown [11] .
8. Fit timing belt in anti-clockwise direction, starting at high-pressure fuel pump sprocket. Ensure belt is taut between sprockets on non-tensioned side.

   NOTE: Ensure arrow on belt faces direction of rotation.

9. Slacken tensioner pulley bolt [6] .
10. Turn tensioner pulley anti-clockwise until pointer at position shown [12] . Use Allen key.
11. Tighten tensioner pulley bolt [6] . Tightening torque: 50 Nm.
12. Hold camshaft sprocket [8] . Tool No.205-072.
13. Tighten camshaft sprocket bolt [9] . Tightening torque: 50 Nm.
14. Remove tools [2] , [3] & [4] .
15. Turn crankshaft almost two turns clockwise.
16. Insert timing pin in cylinder block [2] .
17. Turn crankshaft slowly clockwise to TDC on No.1 cylinder until crankshaft web against timing pin.
18. Fit flywheel locking tool [3] .

    NOTE: Crankshaft web MUST remain locked against timing pin.

19. Ensure tensioner pointer at position shown [12] . If not: Repeat installation procedure.
20. Ensure setting bar can be fitted to rear of camshaft [4] . If not: Repeat installation procedure.
21. Remove tools [2] , [3] & [4] .
22. Fit blanking plug to cylinder block.
23. Install components in reverse order of removal.