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How to Replace timing chain on Ford C-Max 1.6 2005

Ford C-Max 1.6 2005 cambelt change instructions and replacement inteval. Full guide!

Special tools

  • Camshaft setting bar – Ford No.303-376B.
  • Crankshaft timing pin – Ford No.303-748.
  • Holding tool – Ford No.205-072.
  • 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.

Valve timing procedures

How to Replace timing belt on Ford C-Max 1.6 2005
How to Replace timing belt on Ford C-Max 1.6 2005

Removal

WARNING: Crankshaft sprocket NOT keyed to crankshaft.

  1. Raise and support front of vehicle.
  2. Remove:
    • RH front wheel.
    • RH wheel arch liner.
    • Water pump pulley [1] .
    • Auxiliary drive belt(s).
      NOTE: Auxiliary drive belt(s) require cutting and cannot be reused.
    • Alternator.
  3. Disconnect:
    • Crankcase ventilation hose.
    • Camshaft position (CMP) sensor multi-plug.
    • Spark plug leads.
  4. Remove:
    • Cylinder head cover.
    • PAS reservoir. DO NOT disconnect hoses.
  5. Disconnect power steering pressure (PSP) switch multi-plug.
  6. Remove:
    • Coolant expansion tank. DO NOT disconnect hoses.
    • Blanking plug from cylinder block [2] .
  7. Turn crankshaft clockwise until just before TDC on No.1 cylinder.
  8. Fit crankshaft timing pin [3] . Tool No.303-748.
  9. Turn crankshaft slowly clockwise until it stops against timing pin.
  10. Ensure camshaft setting bar can be fitted [4] . Tool No.303-376B.
  11. If setting bar cannot be fitted:
    • Remove crankshaft timing pin [3] .
    • Turn crankshaft one turn clockwise.
    • Fit crankshaft timing pin [3] . Ensure crankshaft web against timing pin.
    • Ensure camshaft setting bar can be fitted [4] .
  12. Support engine.
  13. Remove:
    • RH engine mounting.
    • RH engine mounting bracket.
    • Timing belt upper cover [5] .
  14. Remove:
    • Crankshaft pulley bolt [6] .
    • Crankshaft pulley [7] .
    • Timing belt lower cover [8] .
  15. Push on belt to depress tensioner pulley and insert locking pin [9] . Tool No.303-1054.
  16. Remove timing belt.

Installation

WARNING: Crankshaft sprocket NOT keyed to crankshaft.

  1. Ensure crankshaft timing pin located correctly [3] .
  2. Ensure camshaft setting bar fitted correctly [4] .
  3. Hold camshaft sprockets [10] . Use tool No.205-072.
    NOTE: Use sleeves on holding tool studs to protect camshaft sprockets from damage (part No.E890438S).
  4. Remove bolt of each camshaft sprocket [11] .
  5. Fit new bolt to each camshaft sprocket [11] . Tighten bolts finger tight.
  6. Ensure camshaft sprockets can turn freely without tilting.
  7. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket.
  8. Ensure belt is taut between sprockets.
  9. Remove tensioner pulley locking pin [9] .
  10. Hold camshaft sprockets [10] .
    NOTE: Use sleeves on holding tool studs to protect camshaft sprockets from damage (part No.E890438S).
  11. Tighten bolt of each camshaft sprocket [11] . Tightening torque: 60 Nm.
    NOTE: DO NOT use setting bar to hold camshafts when tightening bolts.
  12. Fit timing belt lower cover [8] .
  13. Check depth of crankshaft threaded hole [12] . Use suitable measuring tool [13] .
    • 42 mm: Use new crankshaft pulley bolt (M12 x 29 mm).
    • 52 mm: Use new crankshaft pulley bolt (M12 x 44,5 mm).
    • 81 mm: Use new crankshaft pulley bolt (M14 x 80 mm).
  14. Fit crankshaft pulley [7] .
  15. Tighten crankshaft pulley bolt [6] . Use new bolt. Tightening torque:
    • M12: 40 Nm + 90°.
    • M14: 100 Nm + 90°. Wait 10 seconds. Tighten crankshaft pulley bolt a further 15°.
  16. Remove:
    • Crankshaft timing pin [3] .
    • Camshaft setting bar [4] .
  17. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
  18. Fit crankshaft timing pin [3] .
  19. Turn crankshaft slowly clockwise until it stops against timing pin.
  20. Ensure camshaft setting bar can be fitted [4] .
  21. If not: Repeat tensioning procedure.
  22. Remove:
    • Crankshaft timing pin [3] .
    • Camshaft setting bar [4] .
  23. Fit blanking plug to cylinder block [2] . Tightening torque: 20 Nm.
  24. 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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