Special Tool(s) / General Equipment 303-1059 Alignment Peg, Crankshaft Timing Belt 303-393 Locking Tool, Flywheel 303-393-01 Adapter for 303-393 303-735 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) -
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.
5. 6. Use the General Equipment: Trolley Jack
7. 8. 9. Use Special Service Tool: 303-735 Alignment Peg, Camshaft.
10. NOTICE: Make sure that the crankshaft is not rotated while the special tool is installed. Use Special Service Tool: 303-1059 Alignment Peg, Crankshaft. 11. Use Special Service Tool: 303-1059 Alignment Peg, Crankshaft., 303-393 Locking Tool, Flywheel., 303-393-01 Adapter for 303-393.
12. NOTICE: Take extra care when handling the crankshaft position (CKP) sensor ring. 13.
Installation 1. 1. NOTE: Make sure that a new component is installed. 2. Torque: 56 Nm 2. 1. 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.
1. Allen key, 6mm 3. Torque: 21 Nm 4. Torque: 50 Nm 5. Remove the special tools. Use Special Service Tool: 303-1059 Alignment Peg, Crankshaft., 303-393 Locking Tool, Flywheel., 303-393-01 Adapter for 303-393.
6. Remove the special tool. Use Special Service Tool: 303-735 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: 303-1059 Alignment Peg, Crankshaft.
9. Install the special tools. Use Special Service Tool: 303-1059 Alignment Peg, Crankshaft., 303-393 Locking Tool, Flywheel., 303-393-01 Adapter for 303-393. 10. NOTE: The special tool can only be installed if the valve timing is correct. Install the special tool. Use Special Service Tool: 303-735 Alignment Peg, Camshaft.
11. 12. Remove the special tool. Use Special Service Tool: 303-735 Alignment Peg, Camshaft. 13. Torque: 7 Nm
14. 1. 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
16. Torque: 90 Nm 17. 1. Torque: 7 Nm 2. NOTE: Make sure that a new component is installed. Torque: Stage 1: 70 Nm Stage 2: 60
18. Remove the special tools. Use Special Service Tool: 303-1059 Alignment Peg, Crankshaft., 303-393 Locking Tool, Flywheel., 303-393-01 Adapter for 303-393. 19. Torque: 40 Nm
20. 1. 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 (414-01 Battery, Mounting and Cables, General Procedures).