Timing Belt. Special Tool(s) / General Equipment Alignment Peg, Crankshaft Locking Tool, Flywheel Adapter for
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1 Special Tool(s) / General Equipment Alignment Peg, Crankshaft Timing Belt Locking Tool, Flywheel Adapter for Alignment Peg, Camshaft Trolley Jack Removal 1. Disconnect battery 2. Remove drive belt 2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW/2.0L Duratorq- TDCi (120kW/163PS) -
2 3. 4. NOTICE: Do not use power tools to remove the bolt. NOTICE: Do not stop loosening the bolt unless you feel high resistance. NOTE: Make sure that the rubber is not damaged. If high resistance is felt heat the bolt for 4 minutes and repeat for another minute if not successful.
3 5. 6. Use the General Equipment: Trolley Jack
4 Use Special Service Tool: Alignment Peg, Camshaft.
5 10. NOTICE: Make sure that the crankshaft is not rotated while the special tool is installed. Use Special Service Tool: Alignment Peg, Crankshaft. 11. Use Special Service Tool: Alignment Peg, Crankshaft., Locking Tool, Flywheel., Adapter for
6 12. NOTICE: Take extra care when handling the crankshaft position (CKP) sensor ring. 13.
7 Installation NOTE: Make sure that a new component is installed. 2. Torque: 56 Nm NOTE: Make sure that a new component is installed. 2. NOTE: Make sure that a new component is installed. 3. NOTE: Only tighten the bolt finger tight at this stage. 4. NOTICE: Take extra care when handling the crankshaft position (CKP) sensor ring.
8 1. Allen key, 6mm 3. Torque: 21 Nm 4. Torque: 50 Nm 5. Remove the special tools. Use Special Service Tool: Alignment Peg, Crankshaft., Locking Tool, Flywheel., Adapter for
9 6. Remove the special tool. Use Special Service Tool: Alignment Peg, Camshaft. 7. NOTICE: Only rotate the crankshaft clockwise. Rotate the crankshaft 4 revolutions. 8. NOTE: The special tool can only be installed if the valve timing is correct. Install the special tool. Use Special Service Tool: Alignment Peg, Crankshaft.
10 9. Install the special tools. Use Special Service Tool: Alignment Peg, Crankshaft., Locking Tool, Flywheel., Adapter for NOTE: The special tool can only be installed if the valve timing is correct. Install the special tool. Use Special Service Tool: Alignment Peg, Camshaft.
11 Remove the special tool. Use Special Service Tool: Alignment Peg, Camshaft. 13. Torque: 7 Nm
12 NOTE: Only tighten the bolts finger tight at this stage. 2. Torque: 133 Nm 15. Lower and remove the Trolley jack. Use the General Equipment: Trolley Jack
13 16. Torque: 90 Nm Torque: 7 Nm 2. NOTE: Make sure that a new component is installed. Torque: Stage 1: 70 Nm Stage 2: 60
14 18. Remove the special tools. Use Special Service Tool: Alignment Peg, Crankshaft., Locking Tool, Flywheel., Adapter for Torque: 40 Nm
15 Torque: 6 Nm 2. Torque: 12 Nm 21. Refer to: Accessory Drive Belt (303-05G Accessory Drive - 2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq- TDCi (103kW/140PS) - - DW, Removal and Installation). Refer to: Battery Disconnect and Connect ( Battery, Mounting and Cables, General Procedures).
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