Special tools
- Crankshaft timing pin – Ford No.303-193 (21-104).
- Flywheel locking tool – Ford No.303-393 (21-168).
- Injection/high-pressure fuel pump sprocket remover – Ford No.303-095 (23-067).
- Universal flange holding wrench – Ford No.205-072 (15-030-A).
- Timing chain front cover alignment tool – Ford No.303-652 (21-230).
- 6 mm drill bit.
General precautions
- Disconnect battery earth lead.
- Remove glow plugs to ease turning engine.
- Turn engine in normal direction of rotation (unless otherwise stated).
- Observe tightening torques.
- If fitted: Mark position of crankshaft position (CKP) sensor before removal.
- Do NOT turn crankshaft via camshaft or other sprockets.
- Do NOT turn crankshaft or camshaft with timing chain removed.
Valve timing procedures
- Removal/installation of timing chain requires:
- Timing belt removal.
NOTE: To gain access to flywheel, starter motor MUST be removed.
- Engine at TDC on No.1 cylinder.
- Insert crankshaft timing pin [1] .
- Install timing chain, sprockets and guide.
- Common rail engines:
- Tighten high-pressure fuel pump sprocket bolts to 24 Nm.
- Install timing chain tensioner [2] . Tightening torque: 65 Nm.
- Non-common rail engines:
- Install injection pump sprocket bolts. Finger tighten bolts.
- Lock injection pump sprocket. Insert 6 mm drill bit [3] .
- Install timing chain tensioner [2] . Tightening torque: 65 Nm.
- Tighten injection pump sprocket bolts to 24 Nm.
- After timing chain cover installation, apply sealant to injection/high-pressure fuel pump outer sprocket bolt holes.NOTE: Always replace injection/high-pressure fuel pump oil seal retainer.
- Install injection/high-pressure fuel pump outer sprocket. Tighten bolts to 42 Nm [4] .
- Fit new crankshaft pulley bolt. Tighten bolt to 100 Nm + 180°.